20120720074027!en Micro-Hydropower Design Aids Manual GIZ 2005 PDF

MICRO-HYDROPOWER DESIGN AIDS MANUAL
Kathmandu, March 2004
Pushpa Chitrakar
Small Hydropower Promotion Mini-Grid Support Programme

Project (SHPP/GTZ) (MGSP/AEPC-ESAP)
Micro-hydropower Design Aids Manual SHPP/GTZ-MGSP/AEPC
TABLE OF CONTENTS
Page No.
TABLE OF CONTENTS I
NOTICE 1
1. INTRODUCTION 2
1.1 GENERAL 2
1.2 OBJECTIVES OF THE DESIGN AIDS 2
1.3 SOURCES OF THE DESIGN AIDS 3
1.4 DESIGN AIDS: TYPICAL DRAWINGS 3
1.5 DESIGN AIDS: SPREADSHEETS 5
1.5.1 Flow chart notations 6
1.5.2 Iterative Processes 6
1.5.3 Macro Security 7
1.5.4 Individual vs. linked spreadsheets 8
1.5.5 User specific inputs 8
1.5.6 Interpolated computations 8
1.5.7 Errors 8
1.5.8 Cell notes 8
1.5.9 Cell Text Conventions 9
1.5.10 Types of input values 11
1.5.11 Pull Down menus and data validation 12
2 DISCHARGE MEASUREMENT 13
3 HYDROLOGY 15
3.1 HYDROLOGY AND NEPALI MHP 15
3.2 HYDROLOGICAL DATA 15
3.3 MEDIUM IRRIGATION PROJECT (MIP) METHOD 16
3.4 WECS/DHM (HYDEST) METHOD 18
3.4.1 Flood Flows: 18
3.5 AEPC MGSP/ESAP GUIDELINES & STANDARDS 19
3.6 PROGRAM BRIEFING & EXAMPLES 20
4 HEADWORKS 24
4.1 INTRODUCTION AND DEFINITIONS 24
4.2 AEPC MGSP/ESAP GUIDELINES AND STANDARDS 24
4.1.1 Weir 25
4.1.2 Intake 25
4.1.3 Intake Trashrack 25
4.3 PROGRAM BRIEFINGS AND EXAMPLES 25
Page : i
5 HEADRACE/TAILRACE 34
5.2 MGSP/ESAP GUIDELINES AND STANDARDS 34
5.2.1 Canal 34
5.2.2 Pipe 34
5.3 PROGRAM BRIEFING AND EXAMPLES 34
5.3.1 Canal 34
5.3.2 Pipe 39
6 SETTLING BASINS 42
6.1.1 Sediment Settling Basins 42
6.2 SETTLING BASIN THEORY 43
6.3.1 Gravel Trap 43
6.3.2 Settling Basin 44
6.3.3 Forebay 44
6.4 PROGRAM BRIEFING AND EXAMPLES 44
6.4.1 Features of the spreadsheet 44
6.4.2 Vertical flushing pipe 45
6.4.3 Spillway at intake 45
6.4.4 Gate 45
7 PENSTOCK AND POWER CALCULATIONS 50

7.3 PROGRAM BRIEFING AND EXAMPLE 50
7.3.1 Program Briefing 50
7.3.2 Typical example of penstock pipe 51
8 TURBINE SELECTION 54
9 ELECTRICAL EQUIPMENT SELECTION 56

9.2.1 Selection of generator size and type 56
9.2.2 Sizing and RPM of Synchronous Generator: 57
9.2.3 Sizing and RPM of Induction Generator: 58
9.3.2 Typical example of a 3-phase 60kW synchronous generator 59
9.3.3 Typical example of a single phase 20kW induction generator 60
Page : ii
TRANSMISSION AND DISTRIBUTION 63

10 LOADS AND BENEFITS 68

10.3.2 Typical example of loads and benefits 69
13. COSTING AND FINANCIAL ANALYSES 71

13.1. INTRODUCTION AND DEFINITIONS 71
13.2. MGSP/ESAP GUIDELINES AND STANDARDS 71
13.3. PROGRAM BRIEFING AND EXAMPLE 71
13.3.1. Program Briefing 71
13.3.2. Typical example of costing and financial analyses 72
13. UTILITIES 73
13.1. INTRODUCTION 73
13. REFERENCES 75
APPENDICES I
LIST OF FIGURES
Figure 1.1: A typical Gravel Trap Drawing............................................................................5
Figure 2.1: Discharge calculations by salt dilution method..............................................14
Figure 3.1: MIP Regions.......................................................................................................16
Figure 7.1: Flow diagram of penstock design....................................................................51
Figure 7.2: Input required for penstock and power calculations......................................52
LIST OF TABLES
Table 1.1: Summary of Drawings .........................................................................................4
Table 1.2: Summary of Spreadsheets...................................................................................5
Table 2.1: Input parameters for Salt Dilution Method........................................................13
Table 3.1: MIP regional monthly coefficients .....................................................................16
Page : iii
NOTICE
These micro-hydropower design aids have been prepared to provide a basis for consultants to undertake
calculations and prepare drawings as per the requirements set aside by Alternative Energy promotion
Centre (AEPC) of His Majesty’s Government of Nepal (HMG/N). It is expected that the use of these
design aids will result in a standard approach to carrying out calculations and drawing on Peltric feasibility
studies and preliminary and feasibility studies of micro-hydro projects.
This manual and any examples contained herein are provided “as is” and are subject to change without
notice. Small Hydropower Promotion Project (SHPP/GTZ) and Mini-Grid Support Programme
(MGSP/AEPC-ESAP) shall not be liable for any errors or for incidental or consequential damages in
connection with the furnishing, performance, or use of this manual or the examples herein.
© Small Hydropower Promotion Project (SHPP/GTZ) and Mini-Grid Support Programme (MGSP/AEPC-
ESAP). All rights reserved.
All rights are reserved to the programs and drawings that are included in the MHP Design Aids.
Reproduction, adaptation or translation of those programs and drawings without prior written permission of
SHPP/GTZ and MGSP/AEPC-ESAP is also prohibited.
Permission is granted to any individual or institution to use, copy, or redistribute the MHP Design Aids so
long as it is not sold for profit, provided this copyright notice is retained.
CONTACT & ACCESS CONTACT & ACCESS

Small Hydropower Promotion Project /GTZ Mini-Grid Support Programme/AEPC-ESAP
PO Box: 1457, PO Box:
KSK Building, Dhobichaur,
Lalitpur, Nepal Lalitpur, Nepal
Tel: 977 1 5546701/5546702 Tel: 977 1 5536843/5539391
Fax: 977 1 5546703 Fax: 977 1 5539392
E-mail: shp@gtz.org.np E-mail: energy@aepc.wlink.com.np
www.gtz.de/nepal/projects/shpp.html www.aepcnepal.org
Page: 1
1. INTRODUCTION
1.1 GENERAL
This Micro Hydropower Design Aids Manual covers the procedural guidelines for using Micro Hydro
Design Aids prepared under the collaboration between Small Hydropower Promotion Project (SHPP/GTZ)
and Alternative Energy promotion Centre (AEPC) of His Majesty’s Government of Nepal (HMG/N). The
Micro hydro Design Aids, which consists of a set of spreadsheets and drawings, has been developed as a
tool to provide quick and reliable means of computing design parameters of different components of the
perspective micro hydropower plants in Nepal.
Small Hydropower Promotion Project is a joint project of His Majesty’s Government of Nepal (HMG/N),
Department of Energy Development (DoED) and German Technical Cooperation (GTZ). Since its
establishment in 2000, this project has been providing its services to sustainable development of small
hydropower projects in Nepal (100kW to 10MW) leading to public private participation and overall rural
development.
Alternative Energy Promotion Centre (AEPC) is a government organization established to promote

alternative sources of energy in the rural areas.
Since the nature of small hydropower and micro-hydropower projects are similar in many aspects,
SHPP/GTZ signed collaboration with the AEPC to help the sector. During the course of supporting and
backstopping micro-hydropower sector as per the scope defined in the collaboration, SHPP helped AEPC
upgrading the existing AEPC guidelines, developing a user-friendly micro-hydropower related
computational tools and typical drawings. These micro hydropower tools (MHP Design Aids) have been
prepared to provide a basis for consultants to undertake calculations and prepare drawings as per the
requirements set aside by AEPC. It is expected that the use of these design aids will result in a standard
approach to carry out calculations and represent the calculations with the help of standard drawings on
Peltric feasibility studies, preliminary feasibility and detailed feasibility studies of micro-hydro projects.
The Design Aids consist of a set of fifteen typical drawings and fourteen typical spreadsheet calculations
useful for Nepali micro hydropower projects up to feasibility study level. During the preparation of these
design aids, special efforts were made so that the skills and knowledge of the practicing stakeholders such
as consultants, manufacturers, inspectors, etc, are not replaced by this design aids. Constant efforts were
equally made to make the design aids simple and user friendly. Since most of the stakeholders are
familiar with Autodesk AutoCad 2000 and Microsoft Excel XP application software, the design aids were
made based on the software.
It is also expected that the stakeholders will be using the electronic version of the design aids. The design
aids are distributed in template/read-only forms so that the original copy is always preserved even when
the users modify them.
The design aids are specifically prepared for micro hydropower schemes up to 100kW. Although, there
are many common approaches and features in all hydropower projects, special care should be taken while
using these aids for bigger schemes if the circumstances are unavoidable.
Preparation and use of the design aids is a continuous process. Therefore, valuable suggestions and
feedbacks are expected from all the stakeholders/users so that the overall quality of the micro hydro
sector is enhanced.
1.2 OBJECTIVES OF THE DESIGN AIDS

The main objective of the design aids is to enhance the quality of the micro hydropower sector in Nepal.
The other objectives or function of the design aids are outlined below:
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1. It should be able to function as a “Time Saver Kit” for precision and speed (e.g. hydrological
calculations based on exact flow measurement date, Q flood off take, friction of penstock, etc.).
2. It should be able to function as references for stakeholders of the micro hydro sector for using and
upgrading their skill and creativity. Any external references that may require referring during
calculations are minimised by incorporating them in the cell notes, tables, pictures, etc.
3. The presented reports by different consultants are uniform and their data presentations are to the
required depth.
4. The design aids should be able to serve as templates and not a readymade design set so that
there are sufficient rooms for further creativity and improvement to tailor to incorporate specific
needs of particular projects.
5. In addition to the objectives stated above, the design aids should equally be handy and user
friendly. The user familiar AutoCad 2000 and MS Excel XP software platforms are used to
develop the design aids.
1.3 SOURCES OF THE DESIGN AIDS

Since the Design Aids was made aiming to enhance the overall quality of the micro hydro sector, the
prudent materials available and applicable for the specific purposes, studies of different preliminary and
feasibility reports of different micro hydro plants, feedbacks suggestions from the stakeholders, etc., are
based during the preparation of the design aids. Review of following sources was utilized during the
designing of the design aids:
1. Updated AEPC micro hydropower guidelines and standards.

2. Review, assessment and appraisal of the more than 250 preliminary feasibility reports, 150
feasibility and about 50 Peltric micro hydropower project study feasibility reports during the on
going SHPP/GTZ-AEPC collaboration.
3. Feedbacks from all the stakeholders such as Reviewers, Consultants, Developers, Manufacturers,
Installers, etc.
4. Experience from other micro, small and large hydropower projects.
5. Standard textbooks, guidelines and standards. These sources are listed in the list of references at
the end of this manual.
1.4 DESIGN AIDS: TYPICAL DRAWINGS

All together, fifteen AutoCad 2000 drawings are prepared and incorporated in the design aids. Since they
are only typical drawings, additions of drawings and their level of details may be changed to fulfil specific
needs of a particular project. During the preparation of these drawings, the level of consistency,
compatibility and the extent of information in the drawings that are appropriate for micro hydropower plants
are considered. Adequate information is incorporated in the drawings so that the presented drawings are
complete and all the stakeholders are able to understand and implement the presented content. The main
features of the presented drawings are:
1. Minimum required details such as plans and adequate cross sections.

2. Recommended values of elements presented in the drawings such as the minimum thickness of a
stone masonry wall, the longitudinal slope of a settling basin, etc.
3. Standard line types and symbols.
4. Elements such as the title box with all the information and controlling signatories; scale; etc.
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5. All drawings with standard layouts for a specific printer (may have to be changed as per the actual
available printer).
While editing the drawing based on the project needs, it should be noted that the dimensions should be
amended along with their geometries. This is especially important so that a 2m long structure is always
longer than a 20cm structure.
The presented drawings cover from intake to transmission line. A set of all the drawings are presented in
the appendix. For an example, a typical drawing of a gravel trap is presented in Figure 1.1. The drawings
that are presented are listed in Table 1.1.
Table 1.1: Summary of Drawings

SN Drawing Name (*.dwg) Remarks
1 01 General Layout General layout showing project components except the
transmission and distribution components.
2 02A Side Intake Plan A general Plan of the headworks including river training,
trashrack, intake, gravel trap and spillway.
3 02B Side Intake Sections A longitudinal section along the water conveyance system
from intake to headrace, two cross sections of weir for
temporary and permanent weirs respectively and a cross
section of spillway.
4 03 Drop Intake Plan A general plan, a cross section across the permanent weir
and a cross section of the drop intake.
5 04 Headrace A longitudinal headrace profile showing different levels along
the chainage.
6 05A Gravel Trap A plan, a longitudinal section and two cross sections.
7 05B Settling Basin A plan, a longitudinal section and two cross sections.
8 06 Headrace Canal Two cross sections for permanent lined and one for
temporary unlined canal.
9 07 Forebay A plan, a longitudinal section, two cross sections and
penstock inlet details.
10 08 Penstock Alignment Longitudinal section of a penstock alignment.
11 09 Anchor & Saddle Plans and sections of two different types of anchor blocks and
Blocks saddle.
12 10 Powerhouse A plan and a section of a typical powerhouse.
13 11 Machine foundation A plan and three sections of a typical machine foundation.
14 12 Transmission A single line diagram if a transmission/distribution system.
15 13 Single line diagram A single line diagram showing different electrical components.
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Figure 1.1: A typical Gravel Trap Drawing
1.5 DESIGN AIDS: SPREADSHEETS

As stated earlier, the MS Excel XP is used to develop the spreadsheets. General features of Excel XP are
utilized while developing the spreadsheets. There are thirteen main spreadsheets each covering a tool
required for covering computations for an element of hydro power schemes. The “Utility” spreadsheet
presented at the end of the workbook covers minor calculations such as the uniform depth of water in a
rectangular canal, loan payback calculations, etc. The list of the presented spreadsheets and their areas
of coverage are presented in Table 1.2.
Table 1.2: Summary of Spreadsheets

SN Name Chapter and Area of coverage
1 Discharge Chapter 2: Computation of river discharge measurement with Salt
dilution method.
2 Hydrology Chapter 3: Hydrological calculations based on MIP and Hydest methods
3 Side Intake Chapter 4: Design of side intakes including coarse trashrack, flood
discharge and spillways.
4 Bottom Intake Chapter 4: Design of bottom intake including flood bypass.
5 Settling Basin Chapter 6: Design of settling basins, gravel traps and forebay with
spilling and flushing systems with spillways, cones and gates.
6 Canal Chapter 5: Design of user defined and optimum conveyance canals with
multiple profiles and sections.
7 Pipe Chapter 5: Design of mild steel/HDPE/PVC conveyance pipes.
8 Penstock Chapter 7: Design of penstock with fine trashrack, expansion joints and
power calculations.
9 Turbine Chapter 8: Selection of turbines based on specific speed and gearing
ratios.
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10 Electrical Chapter 8: Selection of electrical equipment such as different types of

generators, cable and other accessories sizing.
11 Transmission Chapter 9: Transmission / Distribution line calculations with cable
estimation.
12 Load Benefit Chapter 10: Loads and benefit calculations for the first three years and
after the first three years of operation.
13 Costing & Financial Chapter 11: Costing and financial analyses based on the project cost,
financing and annual costs and benefits.
14 Utilities Chapter 12: Utilities such as uniform depth, loan payment calculations,
etc.
Since the design aids are aimed at enhancing the quality of micro hydro up to feasibility study level, the
financing, manufacturing, etc., part are not covered in greater details.
The spreadsheets not only speed up the computational processes with adequate level of precision but
also provide adequate information (printable as well as references such as cell notes, etc). The main
features of the presented spreadsheets are:
1.5.1 Flow chart notations

Standard flow chart notations are used describing the flows of programs and procedures. The following
notations are mostly used:
Start and End
Input
Processing formulas and output
Processing and output from other sub routine
Conditional branching
Flow direction
1.5.2 Iterative Processes

It saves tedious and long iterative/repetitive processes. Repetitive processes are generally error
generating element in human computation and it take considerably longer time. A typical repetitive
process is presented in Figure 1.2.
Is Yes
Assume Xo Y =f(X): X=f`(Y) e=<|Yn+1 –Yn| End
No
X=X+h
Figure 1.2: Iterative process
As shown in the figure, the assumed value of X0 is amended until an accepted error limit is reached. By
default, Excel does not activate this kind of iterative process and generates Circular Reference Error. The
Page: 6
iterative features in Excel can be activated by selecting Calculations tab (Tools->Options-

>Calculations>Tick Iteration (cycles & h)) and checking the iteration box. This feature is activated in Figure
1.3.
Figure 1.3: Activation of iteration (Tools => Option =>Calculations

1.5.3 Macro Security
The spreadsheet contains some visual basic for application functions and procedures. Because of the
safety reasons against viruses, MS Excel disables such VBA functions and procedures by default. For the
proper execution, the security level has to be set to medium so that the users will be cautioned and asked
whether to enable such Macros. Setting security level to medium (Tools => Macros => Security =>
Medium) and enabling the macros of the spreadsheets are required for the proper operation. Setting
security level to medium and enabling the macros are presented in Figure 1.4.
Figure 1.4: Macro security and enabling

macros
Page: 7
1.5.4 Individual vs. linked spreadsheets

By default, the spreadsheets are designed in such a way that it can be used as linked spreadsheets for a
single project. The user does not have to input the linked data such as the name of the project in every
spreadsheet. Some of the other processed data such as the design discharge or flood discharge are also
linked by default. However, the users are free to change these values for specific calculations i.e., the
spreadsheet can also be used as individual spreadsheets for independent calculations. It is
recommended to save an extra copy of the workbook before manipulating such linked cell so that the
saved copy can be used as a workbook with linked spreadsheets for a single project.
1.5.5 User specific inputs

Some of the parameters such as the freeboard, width of a canal, factor of safety for a mild steel penstock,
etc., have their standard optimum values. However, the user may choose to enter specific values of
specific project even if these are not the standard or optimum values. By default, the standard optimum
values are computed. However, the user can input the specific non standard values in the spreadsheets.
1.5.6 Interpolated computations

Some of the parameters such as the coefficient of bend, coefficient of gate discharge, etc., have standard
proven values for standard conditions. However, if the user input value is not of a standard tabulated
value, the interpolated values with the help of curve fitting are used for the calculation. The users are
cautioned to check the validity of such values whenever they encounter them.
1.5.7 Errors
Mainly three types of errors are generally expected. One of them is NAME# error which is caused by not
functioning the custom functions and procedures present in the spreadsheets. In case such an error
occurs, close the workbook, activate the macro security level to medium and enable the macros when
opening the workbook again. A typical NAME# error occurs adjacent to the depth of water during flushing
yfi (m) and d50f during flushing (mm) in the settling basin spreadsheet.
VALUE# error is the other error that is generated by the malfunctioning of circular references. When such
an error occurs, select the error cell, press F2 and press Enter. Q intake Qf cumec in the side intake is
such an error.
REF# error in transmission line computation occurs due to the deletion of unnecessary rows in a branch.
In such an instance, copy the second cell from the second line of any branch.
1.5.8 Cell notes

Based on the requirement for understanding the computational procedures, understanding used formulas,
mandatory requirement set aside by AEPC, references required for deciding proper values and criteria,
sufficient cell notes are provided.
A cell containing a cell formula for calculating the specific speed of a turbine is presented in Figure 1.5.
Similarly, Figure 1.6 presents a basic table for selecting Manning’s coefficient of roughness of a canal.
Page: 8
Cell Formula
Figure 1.5: Cell formula incorporated in a cell note.
1.5.9 Cell Text Conventions

Three different colours are used to distinct three different types of cells. A typical example of colour
coding of cell text is presented in Figure 1.7. The colours and categories of these cells are:
Blue cells: These cells represent the mandatory input cell. The user must input these cells with
the correct values of the scheme data for correct output. The mandatory input includes the name
of the project, head, discharge, etc.
Red cells: These cells are optional input cells. Standard values are presented in these cells. If a
user has sufficient ground to change these values, he or she is allowed to do so by changing these
values. It is worth noting that care should be taken while changing these values. The optional
values/ input include the density of sediment, sediment swelling factor, temperature of water, etc.
Black cells: The black cells represent the information and or output of the computations. For the
sake of protecting accidental and deliberate amendment or change leading to wrong output, these
cells are protected.
Page: 9
Cell Notes
Figure 1.6: A cell note presenting typical values of Manning’s n for different surfaces
Colour
coding
of cell
texts
Figure 1. 7: Colour coding of cell texts
Page: 10
1.5.10 Types of input values
Based on the nature of the input, the inputs are categorised in the following three groups:
1. User or project specific input: The inputs variables that totally depend on the user and or the
project are categorised as the user or project specific inputs. The programs do not restrict on or
validate the values of such inputs. The name of the project, gross head of the projects, etc., are
some of the examples that fall on this category. The length of the crest in the example presented in
Figure 1.8 can have any value hence it is a user specific input.
2. Prescribed Input: Some of the inputs have some standard values. The programs suggest using
such values and giving choices for the user to select. However, the programs do not restrict on or
validate such variables. These inputs are termed as prescribed inputs. With the help of a pull down
menu, the probable type of the surface is presented for deciding the Manning’s coefficient in Figure
1.8. The user does not have to remember the specific values of the type of the surface he is
considering. However, he is free to input any values if he has a very good reason to change them.
3. Mandatory Input: Some inputs can have some specific values and the programs need to validate
such values for proper computations. These values are termed as mandatory inputs. Since Nepal
is divided into seven MIP regions, the MIP region value can have an integer ranging from 1 to 7. In
the example presented in Figure 3.1, the MIP region can have values from 1 to 7, the month can
have a string from January to December and the date can have an inter ranging from 1 to 31. In
case the user enters different values, the program will generate error and prompt for the correct
inputs.
Figure 1.8: Different categories of inputs.
Page: 11
1.5.11 Pull Down menus and data validation

Some of the input cells are equipped with pull down menus to facilitate the users to input standard values
related to the input cell. Pull down can have any user specific values than the stated standard values if
the data validation for that particular cell is not specified. In Figure 1.8, the pull down menu for Manning’s
roughness coefficient (n) in cell B42 is activated. Out of the different surface materials are listed in the pull
down menu, stone masonry surface is selected and the corresponding standard value of the Manning’s
coefficient of roughness of 0.02 is substituted in the corresponding cell. Since the value in this cell is not
restricted, the user can have any values for this cell.
Some inputs such as the name of the month, MIP hydrological

region and dates in Hydrology spreadsheet can have specific
values in their respective cells. Since the outcome of the
computation will be erroneous if the input data does not match with
the desired values, the spreadsheets are designed to reject such an
invalid value and flag the error with suggestions. For instance,
Nepal is divided into seven MIP hydrological regions. It can have a
value from 1 to 7. If a user inputs 8 as the MIP region, the data is
rejected and an error message along with suggestions will be
flagged. This example is demonstrated in Figure 1.9.
Figure 1.9: Different categories of inputs.
Page: 12
2 DISCHARGE MEASUREMENT
Almost all potential micro hydropower project sites are located in remote areas where there is a complete
lack of hydrological information. Tools developed for estimating hydrological parameters are mainly based
on regional correlations. The outputs of these tools are close to the actual parameters for rivers having
bigger (100km2 or more) catchment areas. Since most of the potential micro hydropower plants have
relatively smaller catchment areas, use of these regional regression methods based on at least one set
actual site measurement is recommended in the AEPC guidelines for estimating flow parameters. Bucket
method for flow up to 10 l/s, weir method for a flow from 10 to 30 l/s and for flows larger than 30l/s salt
dilution method (conductivity meter) are recommended.
Since the salt dilution method is quick (less than 10minutes per set of measurement), easier to accomplish
and reliable, its accuracy level is relatively higher (less than 7%) and suitable for smaller fast flowing
streams (up to 2000 l/s), preference should be given to this method. The change of conductivity levels of
the stream due to the pouring of known quantity of predefined diluted salt (50-300gm per 100l/s) are
measured with a standardised (conductivity meter with known salt constant, k) conductivity meter at a
regular interval (e.g., 5 seconds). For more information, please refer to MGSP Flow Verification
Guidelines or Micro Hydro Design Manual (A Harvey).
As per the MGSP guidelines, at least one set of discharge measurement at the proposed intake site
should be carried out between November and May. The discharge calculation spreadsheet presented in
the Design Aids can handle up to four sets of data and the individual as well as the average discharges
are presented as outputs.
The input parameters required for discharge measurement calculation are presented in Table 2.1. The
typical input parameters considered in the example are presented in the adjacent column. The first set
field readings are presented in Table 2.2.
Table 2.1: Input parameters for Salt Dilution Method

SN Input parameters Input for the cited Example
1 Project Upper Jogmai, Ilam
2 Conductivity Meter HANNA Instruments HI 933000
3 Date 12-Jan-04
4 Type of Salt Iyoo Nun
o
5 Conductivity Constant 1.8 at 15 C
o
6 Water temp 15 C
7 Time Intervals (dt) 5sec
8 Weights of salt for sets 1 to 4 () 400g, 1580g and 1795g
9 Readings (m & mbaseline) for sets 1 to 4 Presented in Table 2.2
Table 2.2: First set conductivity reading for Salt Dilution Method Example
Time(sec)
5 10 15 20 25 30 35 40 45 50 55 60 Sum
25 26 27 28 29 30 31 32 32 33 34 34 361
34 35 35 35 35 34 34 34 33 33 33 32 407
Water
32 32 32 31 31 31 31 31 31 30 30 30 372
Conductivity in
mS 30 29 29 29 29 29 29 28 28 28 28 28 344
28 28 27 27 27 27 27 26 26 26 26 26 321
26 26 26 26 26 26 26 25 25 25 257
Total (mS) 2062
Total readings 70
With the input parameters, the discharge at the stream is calculated by the following procedures:
Page: 13
Stream Flow, Q = M x k/A, where

Q = flow in lit/sec
M = mass of the dried salt in mg (i.e.10-6 kg).
k = the salt constant in (mS)/(mg/litre).
A is the area under the graph of conductivity versus time, after excluding the area due to
base conductivity. The units for the area under the graph is sec x mS. The area is
determined as follows:
Area (A) = (Sm– nr x mbaseline) * dt
Weighted averages of the individual flows thus calculated are computed. The outputs of the spreadsheet
are presented in Figure 2.1. The estimated average discharge will further be used by Medium Irrigation
Project Method (MIP) to calculate long term average monthly flows. The calculations procedures for the
first set (Set 1) are:
Area (A) = (Sm– nr x mbaseline) * dt

= (2062-70*25)*5
= 1560 sec x mS
Discharge (Q) = M x k/A

= 400000*1.8/1560
= 461.54 l/s
Discharge Measurement by Conductivity Meter
Project Upper Jogmai, Ilam
Meter HANNA Instruments (HI 933000)
Salt Iyoo Noon
Water temp: 11 deg C Date: 12-Jan-04

Given k 1.8 Time intervals 5 sec
Salt Const. (k) 1.8000

Wt. of Salt 400 gm 1580 gm 1795 gm 0 gm
Nr of data 70 91 106 0
Baseline conductivity 25 24 24 0
Sum of readings 2062 3433 3997 0
Effective Area 1560 6245 7265 0
Discharge 462 l/s 455 l/s 445 l/s 0 l/s
Average Discharve 454 l/s
Discharge Measurement by Conductivity

Meter: Upper Jogmai, Ilam
80
Salt =400gm, A ef f =1560
70 Salt =1580gm, A ef f =6245
Salt =1795gm, A ef f =7265
60 Salt =0gm, A ef f =0
Conductivity m S
50
40
30
20
10
0
0 50 100 150 200 250 300
Time(sec) 350 400 450 500 550 600
Date= 2004/1/12, 11deg C, , HANNA Instrum ents (HI 933000), Iyoo Noon, k=1.8,
Ave. Discharge = 453.89 l/s
Time Reading 1 Reading 2 Reading 3 Reading 4

0 25 24 24
5 26 24 25
10 27 24 25
15 28 24 26
20 29 24 27
25 30 24 29
30 31 24 30
Figure 2.1: Discharge calculations by salt dilution method
Page: 14
3 HYDROLOGY
3.1 HYDROLOGY AND NEPALI MHP

Hydrology is the science that deals with space-time
characteristics of the quantity and quality of the waters of the
earth. It is the intricate relationship of water, earth and Atmosphere
Atmosphere
atmosphere.
As stated earlier, almost all potential micro hydropower project

sites are located in remote areas where there is a complete lack
of hydrological information. According to the ACPC guidelines,
with a set of actual measurement in dry season (November-May),
the mean monthly flows for these sites are estimated by Medium
Hydrology
Irrigation Project (MIP) method Developed by M. Mac Donald in
1990. The flood hazards are generally critical for a project having
a design discharge more than 100 l/s. For such a project the
floods should be calculated by using ‘methodologies for
estimating hydrologic characteristics of ungauged locations in
Nepal” WECS/DHM 1990 Study (Hydest) is recommended. Water
Water Earth
Earth
These factors are incorporated in “Hydrology” spreadsheet. Brief
introduction of these two methods are presented in the
subsequent sub-sections.
Figure 3.1: Hydrology
3.2 HYDROLOGICAL DATA

As presented in figure 3.2, the hydrological data constitute of stream flow records, precipitation and
climatological data, topographical maps, groundwater data, evaporation and transpiration data, soil maps
and geologic maps. Large projects may need all the hydrological data. However, only the first three data
are sufficient for the estimation of MIP monthly flows and Hydest floods in micro hydropower project.
Streamflow
Streamflow Records
Records
Precipitation
Precipitation and
and Climatological
Climatological Data
Data MHP
MHP
Hydrological
Hydrological Data
Data
Topographic
Topographic Maps
Maps
Groundwater
Groundwater Data
Data
Evaporation
Evaporation and
and Transpiration
Transpiration Data
Data
Soil
Soil Maps
Maps
Geologic
Geologic Maps
Maps
Hydrological
Hydrological Data
Data
Figure 3.2: Hydrological Data and MHP
Page: 15
3.3 MEDIUM IRRIGATION PROJECT (MIP) METHOD

This method is developed by M. Mac Donald in 1990. According to this method, Nepal is divided into 7
regions. Based on wading measurements by the Department of Hydrology and Meteorology (DHM,
HMG/N), non-dimensional regional hydrographs were developed for each region. The month of April was
used for non-dimensionalizing. Seven sets of average monthly coefficients for the seven regions for each
month were prepared.
The seven regions are graphically shown in Figure 3.3 and the seven sets of monthly coefficients are
presented in Table 3.1. It is worth noting that these monthly coefficients have to be interpolated to get the
actual monthly coefficients if the flow measurement date is not on the 15th of the month.
Figure 3.1: MIP Regions
Table 3.1: MIP regional monthly coefficients

Month Regions
1 2 3 4 5 6 7
January 2.40 2.24 2.71 2.59 2.42 2.03 3.30
February 1.80 1.70 1.88 1.88 1.82 1.62 2.20
March 1.30 1.33 1.38 1.38 1.36 1.27 1.40
April 1.00 1.00 1.00 1.00 1.00 1.00 1.00
May 2.60 1.21 1.88 2.19 0.91 2.57 3.50
June 6.00 7.27 3.13 3.75 2.73 6.08 6.00
July 14.50 18.18 13.54 6.89 11.21 24.32 14.00
August 25.00 27.27 25.00 27.27 13.94 33.78 35.00
September 16.50 20.91 20.83 20.91 10.00 27.03 24.00
October 8.00 9.09 10.42 6.89 6.52 6.08 12.00
November 4.10 3.94 5.00 5.00 4.55 3.38 7.50
December 3.10 3.03 3.75 3.44 3.33 2.57 5.00
Page: 16
INPUT
INPUT
Low
Low flow
flow measurement
measurement OUTPUT
OUTPUT
MIP
MIP
Measurement
Measurement date
date Mean
Mean monthly
monthly flows
flows
MIP
MIP region
region number
number
Figure 3.4: MIP model
Figure 3.4 represents the flow chart of the MIP model. As shown in the figure, this model takes low flow
measurement, its date and MIP region number as inputs and process them for estimating mean monthly
flows for that region. As stated earlier, the actual measurement date plays an important role in computing
more realistic mean monthly flows. These mean monthly flows are calculated as:
Mean Coeff. for this month by interpolation if the date is not on 15th
April coef = 1/coeff this month
April flow = April coeff * Q
Monthly flows = April flow * coeffs (Qi = QApril * Ci)
Figure 3.5: Need of interpolation for calculating mean monthly coefficient
Interpolation of April 1, 15 and 30 data

Q measured =54 l/s
2
1.9 Q corr for mid month = Q measured * Average Coeff/Actual Coeff 60, 1.88
1.8
1.7
1.6
1.5
45, 1.44
1.4 0, 1.38
1.3
1.2 15, 1.19
1.1
1 30, 1
0 15 30 45 60
March 15 April 1 April 15 April 30 May 15
April 15 Q corr 45.38 54.00 37.50
The importance of considering the actual date of measurement and the need of calculating actual mean
monthly flow of that month are further explained in Figure 3.5. The measured flow is 54 l/s. The corrected
flows for April are 45.38 l/s, 54 l/s and 37.5l /s if they are measured on April 1, 15 and 30 respectively. If
interpolation was not carried out, a feasible project may fail to prove its viability according to the ACPC
criteria or vice-a-versa.
This fact that the mean monthly coefficient calculation plays major role in AEPC acceptance criteria is
illustrated by a following example.
Measured flow for MIP method m3/s: 1
MIP region (1 -7): 3
Page: 17
Area of basin below 3000m elevation A3000 km2: 65

Turbine discharge m3/s: 1.173
Water losses due to evaporation/flushing %: 15%
Figure 3.6 is the graphical representation of the outcome of the MIP method. The measurement date
namely on April 1, 15 and 30 are considered and the errors generated by using different dates are
presented. The design flow exceeds 11 months and fulfills the AEPC criteria if it is measured on either
April 1st or April 15th. However, the design flow exceeds only 10 months and does not meet AEPC criteria
if it is measured on either 1st or 30th of April.
E rro rs G e ne rate d b y u sin g mid mo nthly flow s

30
1 -A pr
25
1 5 -A p r
3 0 -A p r
Q dive rted
20
Discharge (m 3/s)
15
10
0
1 2 3 4 5 6 7 8 9 10 11 12
M ONTH
Figure 3.6: Effect of interpolation on mean monthly flows
3.4 WECS/DHM (HYDEST) METHOD

The WECS/DHM (Hydest) Method, which is also known as “Methodologies for estimating hydrologic
characteristics of ungauged locations in Nepal” is developed by WECS/DHM in 1990. Long term flow
records of DHM stations (33 for flood and 44 for low flow) were used to derive various hydrological
parameters such as the monsoon wetness index (June-September mm precipitation). The entire country is
considered as a single homogenous region. This method generally estimates reliable results if the basin
area is more than 100 km2 or if the project does not lie within Siwalik or Tarai regions.
Since the instantaneous and daily floods of 20-year return period are recommended to use while
designing Nepali micro hydro structures, the flood calculations methods recommended by this method are
used in the presented spreadsheet.
3.4.1 Flood Flows:

The catchment area below 3000 m contour line is used for the estimation of floods of various return
periods. This elevation of 3000m is believed to be the upper elevation that is influenced by the monsoon
precipitation. This method has to be used with caution for catchments that have a significant area above
the snowline. The 2-year and 100-year flood can be calculated using following equations:
Q2 daily = 0.8154 x (A below 3000 m +1) 0.9527
Page: 18
Q2 inst = 1.8767 x (A below 3000 m+1)0.8783
Q100 daily =4.144 x (A below 3000 m +1)0.8448
Q100 inst = 14.630 x (A below 3000 m+1)0.7343
Flood peak discharge, QF, for any other return periods can be calculated using:
QF = e
(lnQ 2 + S×s
lnQF
)
Where, S is the standard normal variant for the chosen return period, from Table 3.2, and
æ Q100 ö
ln çç ÷÷
slnQF = è Q2 ø
2.326
Table 3.2: Standard normal variants for floods

Return period (T) (yrs) Standard normal variant (S)
2 0
5 0.842
10 1.282
20 1.645
50 2.054
100 2.326
INPUT
INPUT OUTPUT
OUTPUT
Total
Total catchment
catchment area
area (MMF
(MMF &
& FDC)
FDC) *Mean
*Mean monthly
monthly flows
flows
Hydest
Hydest Flood
Area
Area below
below 5000m
5000m (LF)
(LF) Flood flows
flows (2-100
(2-100 yrs)
yrs)
Area
Area below
below 3000m
3000m (FF)
(FF) Low
Low flows(1,7,30
flows(1,7,30 &
& monthly)
monthly)
*Monsoon
*Monsoon wetness
wetness index
index (MMF
(MMF &
& FDC)
FDC) Flow
Flow duration
duration (0-100%)
(0-100%)
Monsoon
Monsoon wetness
wetness index=(Jun-Sept)
index=(Jun-Sept) mm
mm ** Area
Area =>100km
=>100km22
Figure 3.7: Hydest Model
As shown in Figure 3.7, the Hydest method requires different catchment areas and monsoon wetness
index as inputs to estimate different hydrological parameters such as the mean monthly flows, floods, low
flows and flow duration curve. The hydrological parameters computed by this model are comparable to
the actual parameters for a total catchment area close to or more than 100km2.
3.5 AEPC MGSP/ESAP GUIDELINES & STANDARDS

The guidelines and standards for subsidy approval for the construction of micro hydropower projects in
Nepal can be summarised as:
1. Discharge measurement at the proposed intake site should be between November and May.
2. The recommended discharge measurement methods for different discharges are:
1. Bucket collection < Weir >Salt dilution
Page: 19
2. 10lps < Q >30lps

3. Mean monthly flows should be computed by using MIP method. Alternatively, HYDEST method
may be used for catchment area equal to or more than 100 km2.
4. The design flow should be available at least 11 months in a year (i.e., the probability of
exceedance should be 11 months or more). The design flow for sizing installed capacity (Qd)
should not be more than 85% of the 11-month exceedance flow. Loses and environmental
releases should also be considered if it exceeds 15% of the 11-month exceedance.
5. There is a provision of ±10% tolerance on Qd at the time of commissioning a plant.
6. Construction of flood wall against annual flood is recommended if the design flow exceeds 100 l/s.
3.6 PROGRAM BRIEFING & EXAMPLES

As per the standards and guidelines, the proposed spreadsheet is designed to compute MIP mean
monthly flows and exceedance of the design flow, Hydest floods and design discharges for different
components of a micro hydro schemes. For simplicity, the program considers 30 days a month for all the
months. The flow chart for the proposed hydrological calculations are presented in Figure 3.8.
Start
Project name, location, Q designed

river, Qd, % losses & MGSP
Q diverted
Q measured, Q losses
date measured, MIP Q release
Is No
MIP region from Q monthly Q available
A 3000 the attached map Q exceedance
Given?
Yes Monthly
Hydrograph Q
Hydest
A 3000 Flood flows
End
Figure 3.8: Flow chart of Hydrology spreadsheet
A typical example of the spreadsheet including inputs and outputs are presented in Figure 3.9. The
information required for computations such as the MIP regions, etc., are included in the spreadsheet. The
MIP region map shows that this project lies in MIP region 3. The measured discharge of 80 l/s in March
23 shows that the project is proposed to utilize a small stream. Although the floods are not critical to the
project, they are calculated for sizing the floodwall and other structures. Although the estimated design
discharge is only 80 l/s, the probability of exceedance for this design discharge is only 10 months and
hence does not qualify AEPC acceptance criteria. For AEPC to qualify this project, the turbine design
discharge should not exceed 73.389 l/s. The procedures for the calculations are:
MIP mean monthly calculations:

Corrected coefficient and mid month discharges (Kc December) for Region 3:
Since the measured date of March 23 lies in between March 15th and April 15th,
K March = 1.38
K April = 1.00
Kc March = K March+ (K April -K March)*(Date -15)/30

= 1.38 + (1.00-1.38)*(23-15)/30
Page: 20
= 1.2787
Q March = Q measured *K March /Kc April

= 80 *1.38/1.2787
= 86.34 l/s
Q April = Q March /K March

= 86.34/1.38
= 62.57 l/s
Q May = Q April *K May

= 62.57 * 1.88
= 117.62 l/s
Other mid monthly discharges are calculated similar to the discharge calculation for
the month of May.
Hydest flood flows:

The 2-year and 100-year floods are:
Q2 daily = 0.8154 x (A below 3000 m +1) 0.9527

= 0.8154 * (1.5+1) 0.9527
= 1.952 m3/s
Q2 inst = 1.8767 x (A below 3000 m)0.8783

= 1.8767 x (1.5+1)0.8783
= 4.197 m3/s
Q100 daily =4.144 x (A below 3000 m +1)0.8448

=4.144 x (1.5 +1)0.8448
= 8.987 m3/s
Q100 inst = 14.630 x (A below 3000 m+1)0.7343

= 14.630 x (1.5+1)0.7343
= 28.669 m3/s
Peak discharges for other return periods are calculated by using these formulas:
æ Q100 ö
ln çç
è Q2 ø
÷÷
QF = e
(lnQ 2 + S×s
lnQF
)
slnQF =
2.326
Q20 daily = EXP(LN(1.952 )+ 1.645*(LN(8.987/1.952)/2.326))

= 5.747 m3/s
Q20 inst = EXP(LN(4.197 )+ 1.645*(LN(28.669/4.197)/2.326))

= 16.334 m3/s
Different discharge calculations (as per AEPC criteria are presented for examples):
Qturbine = 85% of the 11 month flow exceedance from the MIP flow if the designed
flow is higher or the design flow.
= 73.389 l/s (since the design flow is higher and 10 month exceedance only)
Qdiverted = Qturbine / (1-%losses)

= 73.389 / (0.95)
Page: 21
= 77.252 l/s
Qlosses = Qdiverted -Qturbine

= 77.252-73.389
= 3.863 l/s
Qrelease = Qmin MIP *%release

= 62.57 * 0.05
= 3.128 l/s
Qrequired at river = Qdiverted + Qrelease

= 77.252+3.128
= 80.380 l/s
A hydrograph including the design flow, exceedance of the proposed design flow and the flow acceptable
for AEPC is presented in Figure 3.9.
Page: 22
H Y D R OLOG I CAL CALCU LATI ONS F OR U NG AU G E D MH P R I VE R S

Project: Chhyota MHP
INPUT
R iver name : Chhyota Khola
Location : Borang, Sertung VCD-2, Dhading
Measured flow for MI P method l/s: 80
Month and day of flow measurement: March 23
MI P region (1 -7) : 3
Area of basin below 3000m elevation A 3000 km 2 : 1.5
Turbine discharge Qd l/s: 80
Water losses due to evaporation/flushing/seepage % : 5%
D ownstream water release due to environmental reasons % : 5%
OUTPUT
MI P monthly average discharge H ydest F lood Flows
Month D ischarge (l/s) R eturn Period (yrs) Flood D ischarge (m 3 /s)

January 169.55 D aily I nstantaneous
February 117.62 2 1.952 4.197
March 86.34 20 5.747 16.334
April 62.57 100 8.987 28.669
May 117.62
June 195.83 D ischarge (l/s) D esigned As per MG SP
July 847.13 Qturbine 80.000 73.389
August 1564.13 Q diverted 84.211 77.252
September 1303.23 Q losses 4.211 3.863
October 651.93 Q release 3.128 3.128
November 312.83 Q required 87.339 80.380
December 234.62 Q exceedence (month) 10 11
Annual av 471.950 Q turbine for 11m 77.922
Long Term Average Annual Hydrograph of Chhyota Khola river, Chhyota MHP
1800
1600 MIP Flow s

Q design =80 l/s w ith 10-month exceedence
1400 Q as per MGSP =73.389 l/s w ith 11-month exceedence
1200
Discharge (l/s)
1000
800
600
400
200
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
MONTH
Figure 3.9: Typical example of a hydrological parameters calculation spreadsheet “Hydrology”
Page: 23
4 HEADWORKS
4.1 INTRODUCTION AND DEFINITIONS
Headworks
A headworks consists of all structural components required for safe withdrawal of desired water from the
river into a canal/conduit. Intake, weir, protection works, etc., are the main structural components.
Indicators of an ideal headworks can be summarized as:
1. Withdrawal of the desired flow (i.e., Qdiverted and spilling in case of flood).
2. Sediment bypass of diversion structure (Continued sediment transportation along the river).
3. Debris bypass (Continued debris bypass without any accumulation).
4. Hazard flood bypass with minimum detrimental effects.
5. Sediment control at the intake by blocking/reducing sediment intake into the system).
6. Settling basin control (settling and flushing of finer sediments entered into the system through
intakes or open canals).
Intake
An intake can be defined as a structure that diverts water from river or other water course to a conveyance
system downstream of the intake. Side intake and bottom intake are the common types of river intakes
that are used in Nepali micro hydropower schemes.
Conveyance Intake is an intake which supplies water to a conveyance other than the pressure conduit to
the turbine. Power Intake is an intake which supplies water to the pressure conduit to the turbine.
Side Intake
A structure built along a river bank and in front of a canal / conduit end for diverting the required water
safely. Side intakes are simple, less expensive, easy to build and maintain.
Bottom/Drop/Tyrolean/Trench Intake
A structure built across and beneath a river for capturing water from the bed of the river and drops it
directly in to headrace. These are mainly useful for areas having less sediment movement, steeper
gradient, and surplus flow for continual flushing. Inaccessibility of trashrack throughout the monsoon
season and exposure of the system to all the bed load even though only a small part of the water is drawn
are the common problems/drawbacks of drop intakes.
Weir
A weir is a structure built across a river to raise the river water and store it for diverting a required flow
towards the intake.
Protection Works
Protection works are the river protection and river training works to safeguard the headworks against
floods, debris and sediments.
Trashrack
A structure placed at an intake mouth to prevent floating logs and boulders entering into headrace.
Coarse trashrack and fine trashrack are provided at the river intake and penstock intake respectively.
4.2 AEPC MGSP/ESAP GUIDELINES AND STANDARDS

The requirements set for weir, intake and trashrack are briefly outlines in this section.
Page: 24
4.1.1 Weir
· Type: A weir can be either temporary or permanent in nature. A dry stone or gabion or mud stone
masonry can be termed as temporary weir whereas a cement masonry or concrete weir can be
termed as a permanent weir.
· Location: It is recommended that the weir should be 5m to 20m d/s of intake. This will assure that
water is always available and there is no sediment deposit in front of the intake. A narrow river
width with boulders is preferable for weir location.
· Height: The weir should be sufficiently high to create enough submergence and driving head.
· Stability: Permanent weir should be stable against sinking, overturning and sliding even during the
designed floods.
4.1.2 Intake
· Type: Side intake is suitable for all types of river categories whereas the drop intake is
recommended for rivers having longitudinal slopes more than 10%, less sediment and excess
flushing discharge. The side intake is generally is of rectangular orifice type with a minimum of
50mm submergence. The side intake should be at:
o Straight river u/s & d/s of the intake.
o Alternatively, on the outer side of the bend to minimize sediment problems and maximise
the assured supply of desired water.
o Relatively permanent river course.
o By the side of rock outcrops or large boulders for stability and strength.
· Capacity: According to the flushing requirement and tentative losses the intake has to be oversized
than the design flow by about 10% to 20% (or Qdiverted).
· A course trashrack should be provided to prevent big boulders and floating logs from entering into
the headrace canal.
· A gate/stop log should be provided to regulate flow (adjust/ close) during operation and
maintenance.
· To optimize the downstream canal and other structures, a spillway should be provided close to the
intake.
4.1.3 Intake Trashrack

The recommended intake coarse trashrack is made of vertical mild steel strips of 5*40 to 5*75. The
clear spacing between these strips should not exceed 75mm. The approach velocity should be less
than 1.0m/s. For transportation, the weight of a piece of trashrack should not exceed 60 kg. With
respect to the combined effect of racking and hydraulic purposes, placing of trashrack at 3V:1H is
considered to be the most optimum option.
4.3 PROGRAM BRIEFINGS AND EXAMPLES

There are two spreadsheets for designing side intake and bottom intake respectively. The first part of the
side intake calculates the trashrack parameter while the second part of it calculats side intake parameters
including spillways for load rejection and flood discharge off-take. The second spreadsheet calculated the
design parameters for a drop intake.
Since most of the program flow chart in this section is self explanatory or the calculation procedures are
familiar to most of the practicing stakeholders, only important points are explained.
Page: 25
Figures 4.1 to 4.7 presents the assumptions, flow charts and typical examples for calculating trashrack
parameters, side intake and drop intake dimensioning.
Figure 4.1: Trashrack parameters
Start
K = (hf + hb)/(Vo^2/2g)
Project name, location,
river, Trashrack coefficient kt
Bar thickness t mm Is Yes
Clear spacing of bars b mm cleaning K1=0.3
Approach velocity Vo m/s manual
Angle of inclination from hor f deg No

Ht of trashrack bot from river bed ht K1=0.8
Flow deviation b deg K1 MHP = 0.55
Design Discharge Qd cumec

A surface= 1/K1 * (t+b)/b * Q/Vo * 1/sin f
h friction = kt * (t/b)^(4/3) * (Vo^2/2/g) * sin f h submerged = hr –ht, hr from intake cal
B = S/(h/sinf)
h bend = Vo^2 /2/g * sin b

hl= hf + hb End
Figure 4.2: Flow chart for trashrack calculations
The trashrack coefficients for different cross section of the bars are presented in the pull down menu.
Typical bar thickness, clear spacing and approach velocity are suggested in the respective cell notes.
It can be seen from the flow chart that the trashrack losses constitute of frictional and bend losses. The
frictional losses depend on the geometry of trashrack such as the trashrack coefficient, thickness and
clear spacing of bars, inclination of the trashrack and the approach velocity. The bend loss depends on
the hydraulics of the approaching flow such as the approach velocity and its deviated direction with
respect to the normal of the trashrack surface.
Page: 26
The trashrack surface area coefficient K1 for automatic racking is 0.8 whereas it is 0.3 for manual racking
suggesting that the racking area for manual operation to recommended surface area is 3.33 times more
than the theoretical area. Manual racking is recommended for Nepali MHPs. Since the consequence of
temporary reduced trashrack area in micro hydro is not severe and the trashrack sites are generally
accessible to operators all the year, the average of automatic and manual racking coefficient is taken for
practical and economic reason.
Flood
ht
Figure 4.3: Side intake parameters
A typical side intake parameters considered in the spreadsheet are presented in Figure 4.3. The design of
side intake parameters are presented in the flow chart in Figure 4.4. An example is presented in Figure
4.6. The design processes for the calculations of a typical side intake are also presented.
Trashrack Design:
Head losses,
h friction = kt * (t/b) (4/3) * (Vo 2/2g)* sin f
= 2.4*(4/25) (4/3) * (0. 5 2/2/9.81)* sin 60o
= 0.0023m
h bend = (Vo 2/2g)* sin b

= (0. 5 2/2/9.81)* sin 20o
= 0.0044m
h total = h friction + h bend

= 0.00232 + 0.0044
= 0.0067m
A surface S = 1/k1*(t+b)/b * Q/Vo * 1/ sin f

= 1/0.55*(4+25)/25*0.077*1/ sin 60o
= 0.3763 m2
Page: 27
Start Orifice Canal & Spillway River

V coeff c, Vo, n, Spillway above NW L Crest length L
d/s submergence hsub, Cd spillway Qf flood
H from canal bed h bot, Freeboard h fb1
height H canal width d/s of orifice
hc=hsub+H+hbot
h overtop = 50% (FB - spillway dh = (Vo/c)^2 / 2g
crest height above NW L) hr = hc + dh
Ls 100% =Qf/C/(2*h overtop)^1.5, hw = hr+0.1
End Ls=max(Ls1 =Qf/C/h overtop^1.5, Yes
Is
Ls2 =2*(Qf-Qd)/C/h overtop^1.5) W c provided? W c=W c
Ls1=>obstruction d/s=> h ot const
Circular references (flood): No

dhf = hrf -hcf W c=2*hc
Qo = A * C * (2*g*dhf)^0.5
hcf = (Qo*n/2^(1/3)/SQRT(1/S))^(3/8)
1/S = 1/{Q * n * P^2/3 /A^5/3 }^2
Vof =c*SQRT(2*g*dhf)
A = Q/V, B = A /H
FB = FB if provided
ycf = (Qf^2/L^2/g)^(1/3)
Or else M in(300, 0.5*hc))
hrf = hw+yc
Figure 4.4: Flow chart for side intake calculations
Width B = S/(h/ sin f)

= 0.3763/(.3/ sin 60o)
= 1.09 m
Side Intake calculations:
Normal condition:
Depth @ canal (hc) = h submergence + height of orifice + height of orifice sill from bottom of
the canal
= 0.05+0.2+0.2
= 0.45m
Driving head (dh) = (Vo/c)2/2/g

= (1.2/0.8)2/2/9.81
= 0.115 m
Head at river (hr) = hc+dh (this value can be provided)

= 0.45+0.115
= 0.565 m
Height of weir (hw) = hr +0.1

= 0.565+0.1
= 0.665 m
Page: 28
Side Intake with orifice Design

Chhota MHP
Design Coarse Trashrack

Flood Level Orifice (H*B)
Min 100 thick & 1000 wide
Normal walkway Rcc slab
river level 1
Weir Crest 3
h rf hr h sub h cf
River bed Gravel Flushing Gate hc Canal
hbot
Gravel trap (if needed)
1:30
Compacted earth/200mm stone soling
Trashrack calculations
Input Output
Trashrack coeffieient kt 2.4 2.4
Bar thickness t mm 4.00 Headloss due to friction hf m 0.0023
Clear spacing of bars b mm 25.00 Headloss due to bends hb m 0.0044
Approach velocity Vo m/s 0.50 Headloss coeff K 0.5226
Angle of inclination from horizontal f deg 60.00 Total headloss ht m 0.0067
Flow deviation b deg 20.00 Surface area A surface m2 0.3750
Design Discharge Qd cumec 0.077 Vertical height h m 0.3647
Height of trashrack bottom from river bed ht 0.20 Trashrack width B m 0.89
Orifice Calculations for (B = 2H or provided) rectangular canal downstream of orifice

Input
Orifice River
Velocity coeff of orifice c 0.8
0.8 Crest length L m 5.000
Velocity through orifice Vo m/s 1.2 Provided Q flood m3/s 10.000
Manning's coeff of roughness 0.02 0.02 Q flood m3/s (Q20 for MHP with Qd>100) 16.334
Downstream submergence depth hsub m 0.050 Used Q flood 10.000
Orifice height H m 0.200 Canal & Spillway
Height of orifice from canal bed h bot m 0.200 Spillway crest height above NWL m 0.050
Provided water depth in the river hr (m) 0.000 Spillway discharge coeff 1.6
1.6
Provided canal width (m) 0.500 Provided Freeboard h fb1 m 0.300
Output
Normal Condition Flood
Canal witdth d/s of orifice 0.500 Critical depth of water at crest yc m 0.742
1/Slope of canal immediately d/s of orifice 1865 Flood head at river hf r = hw+yc m 1.406
Depth of water in canal hc m 0.450 Head difference dhf 0.916
Free board in canal h fb m 0.300 Velocity through orifice Vof m/s 2.544
Area of orifice A m2 0.064 Q intake Qf cumec 0.218
Width of orifice B m 0.321 Depth of water at canal (hc f) m 0.490
Actual velocity through orifice Vo act m/s 1.200
Canal width Wc m 0.500 Spillway
Water level difference dh m 0.115 Ls for Qf m (d/s Obs & 100% hot -50) 1.521
Water depth in the river hr = hc + dh m 0.565 Length of spillway Ls1 for Qf m (d/s Obs) 3.078
Height of weir (hw = hr+0.1) m 0.665 Length of spillway Ls2 for Qf-Qd m 3.978
Spillway overtopping height h overtop m 0.125 Designed spillway length Ls m 3.978
Figure 4.5: An example of side intake calculations
Page: 29
Orifice area (A) = Q/V

= 0.77/1.2
= 0.064 m2
Orifice width (B) = A/H

= 0.064/.2
= 0.322 m
Flood:
Critical depth at crest (yc)= (Qf2/L2/g)1/3
= (102/52/9.81)1/3
= 0.742 m
Head at river (hf r) = hw+yc

= 0.665+0.742
= 1.407 m
Water depth at canal during flood (by equating and iterating flow coming from orifice to that of
canal flow) (hcf) = 0.490m
Q intake (Qf) = 0.218 m3/s
Spillway overtopping height (h overtop) = 50%(Free board –h nwl)

= 0.5*(.3-.05)
= 0.125 m
Spillway length 100% (Ls for Qf) = Qf/C/(2*h ot)1.5

= 0.218/1.6/(2*0.125)1.5
= 1.525 m
Spillway length 50% = Qf/C/(h ot)1.5

= 0.218/1.6/(0.125)1.5
= 3.078 m
The cell containing the depth of water at canal hcf (m) sometimes can generate VALUE# error. Should
such an error occur, select the cell, press F2 key and Enter respectively.
Care should be taken while designing spillway lengths. Ls for Gfm (d/s Obs & 100% hot -50) is only
applicable when full downstream obstruction for flood off-take is provided with the help of stop logs or
gates. Otherwise, the gradually varying water profile at the spillway has to be considered.
Drop Intake calculations:
The example presented in Figure 4.7 follows the procedures presented in Figure 4.6. Although the
calculation procedures for the drop intake are relatively straight forward and simple, it has more
restrictions and limitations regarding the stream geometry and operational conditions.
Based on the flow conditions and the slope of rack the flow immediately upstream of the rack may be
either critical or sub-critical. Critical depth at the entrance of the rack has to be considered if the rack is
steeper (more than 15o). For more details, please refer to EWI UNIDO Standard.
The main differences for considering critical flow and normal flow condition are presented in the Table 4.1.
In the presented spreadsheet, the critical depth of the flow upstream of the intake is calculated and
presented if normal flow (sub-critical) is considered.
Page: 30
River Trashrack
Start
River W idth (Br) Aspect ratio (L across river/B along river)
Head of u/s water (ho) Design Discharge (Q)
U/s water velocity (vo) Gradient (b) deg, Contraction coeff (m)
River gradient (i) degrees W itdth/diameter (t), Clearance (a)
hof, vof
d = t + a, he = ho = vo^2/2g
X = =0.00008*b^2 - 0.0097*b + 0.9992
c =0.6*a/d*(COSb)^1.5
Yes h = ¾*Yc
Yc Considered?
Qo u/s = v (9.81 * ho 3 * Br 2 )
No Qof u/s = v (9.81 * hof 3 * Br 2 )
h =2/3*c*he
Qo u/s = Br * ho * vo
Qof u/s = Br * hof * vof
L =SQRT(3*Q/(2*c*m*L/B ratio*SQRT(2*9.81*h)))
L' = 120% of L, b = L/B ratio * L”, A=L'*b
Qu u/s = Qo u/s – Qdesign
h f = 2/3*c*(ho + vo f^2/2g)
End Q in f= 2/3*c*m*b*L'*SQRT(2*9.81*h f)
Quf d/s = Qof u/s of intake -Q in f
Figure 4.6: Parameters and flow chart of drop intake design
Table 4.1: Drop intake and upstream flow

Parameters Normal flow Critical Depth considered
Velocity head (h) = 2/3 * c * he = ¾ * Yc
Qo u/s of intake (m3/s) normal = Br * Ho * Vo = SQRT(9.81*ho 3*Br 2)
Qo u/s of intake (m3/s) flood = Br * Ho f * Vo = SQRT(9.81*ho f 3*Br 2)
The calculations presented in Figure 4.7 are varified in the following section. In this example the flow
upstream of the intake is considered to be of critical.
Normal condition:
c/c distance of trashrack bars d (mm)
=t+a
= 60+30
= 90mm
Kappa (c) = 0.00008*b^2 - 0.0097*b + 0.9992 (by curve fitting)

= 0.00008*36^2 - 0.0097*36 + 0.9992
= 0.749
Velocity head (h) m = ¾ * of Yc

= ¾ * 0.226
= 0.170 m
Correction factor (c) = 0.6*a/d*(COSb)^1.5

= 0.6*30/90*(Cos 36)^1.5
= 0.146
Length of Intake (L) m = SQRT(3*Q/(2*c*m*L/B ratio*SQRT(2*9.81*h)))

= SQRT(3*2.7/(2*c*0.85*3.546468*SQRT(2*9.81*.170)))
= 2.249 m
Page: 31
Bottom/Drop Intake
Gothi MHP
Input Critical Depth Considered 1

River Width flood (Brf) m = 20
River Width (Br) m = 8 ho flood m = 3.000
Head/Critical Depth of u/s water (ho)m = 0.226 vo flood m/s = 4
Upstream water velocity (vo) m/s = 1.494 Design Discharge (Qd), m3/s = 2.7
River gradient (i) degrees = 9.462 Trashrack witdth/diameter (t) mm = 60
Trashrack gradient (b) deg = 36 Trashrack clearance (a) mm = 30
Contraction coeff (m) = 0.85
Aspect ratio (Length across the river/Breadth along the river) = 3.546468
Output
c/c distance of trash rack bars d mm = 90 Area of intake (A=L' *b) m2 = 21.522
Total head (he) m = 0.340 Qo u/s of intake (m3/s) normal = 2.700
kappa (c) = 0.749 Qu d/s of intake (m3/s) normal = 0.000
velocity head (h) m = 0.170 h flood = 1.906
Correction factor ( c) = 0.146 Qof u/s of intake = Br * hof * vof (m3/s) = 325.497
Length of intake (L) m = 2.249 Q in flood m3/s = 10.855
Factored length (L' = 120% of L) m = 2.699 Quf d/s of intake (m 3/s) = 314.641
Intake length across the river (b) m = 7.975
Figure 4.7: An example of drop intake
Factored length (L’) m = 120% of L

= 1.2*2.699
= 2.699 m
Page: 32
Intake length across the river (b) m

= L/B ration * L
= 3.546468*2.249
= 7.975m
Area of intake (A) m2 = L’ * b

= 2.699 * 7.975
= 21.522 m2
Qo u/s of intake (m3/s) = SQRT(9.81*ho 3*Br 2)

= SQRT(9.81*.226 3*8 2)
= 2.7 m3/s
Qu d/s of intake (m3/s) = Qo u/s -Qd

= 2.7-2.7
= 0 m3/s
Intake length across the river (b) m

= L/B ration * L
= 3.546468*2.249
= 7.975m
Flood:
h flood (hf) m = 2/3*c*(ho flood+vo flood^2/2g)
= 2/3*0.749*(3+4^2/2/9.81)
= 1.906 m
Qo u/s of intake (m3/s) = SQRT(9.81*hof 3*Br 2)

= SQRT(9.81*1.9063*20 2)
= 325.497 m3/s
Qo in (off-take) (m3/s) = 2/3*c*m*b*L' *SQRT(2*9.81*h flood)

= 2/3*0.146*0.85*7.975*2.699*SQRT(2*9.81*1.906)
= 10.855 m3/s (this discharge can be reduced by introducing a throttling
pipe d/s of the intake)
Qu d/s of intake (m3/s) = Qo u/s -Qd

= 315.497-10.855
= 314.641 m3/s
Page: 33
5 HEADRACE/TAILRACE

A headrace or tailrace can be defined as a conveyance system that conveys designed discharge from one
point (e.g. intake) to another (e.g. forebay). Generally a canal is used in all cases whereas a pipe is used
for specific e.g. difficult terrain. A canal can be unlined (earthen) or lined (stone masonry or concrete).
The typical canal cross sections used in micro hydropower schemes can be rectangular or trapezoidal or
triangular or semi-circular in shape. The pipes used in MHP can be of HDPE or mild steel and it can be
either open or buried.
For computing head losses, Manning’s equation is used for canal whereas Darcy-Weisbach equation is
used for pipe.
5.2 MGSP/ESAP GUIDELINES AND STANDARDS
5.2.1 Canal
a) Capacity: The canal should be able to carry the design flow with adequate freeboard, escapes to
discharge excess flow. A canal should generally be able to carry 110 to 120 % the design
discharge.
b) Velocity: Self cleaning but non erosive (≥ 0.3m/s).
c) Unlined canal: In stable ground and Q ≤ 30 l/s
d) Lined canal: 1:4 Stone masonry / Concrete (short: crossings or unstable ground). It is
recommended to minimize seepage loss and hence minimize the subsequent landslides.
e) Sufficient spillways and escapes as required.
f) Freeboard: Minimum of 300mm or half of water depth.
g) Stability and Safety against rock fall, landslide & storm runoff.
h) Optimum Canal Geometry: Rectangular or trapezoidal section for lined canal and trapezoidal
section for unlined canal are recommended.
5.2.2 Pipe
a) PVC/HDPE: Buried at least 1m into ground.

b) Steel/CI: As pipe bridge at short crossings/landslides.
c) Pipe inlet with trashracks for a reach of more than 50m and 1.5*v2/2g submergence.
d) Provision of air valves and wash outs where necessary.
5.3 PROGRAM BRIEFING AND EXAMPLES
5.3.1 Canal
a) Permissible erosion free velocities for different soil conditions:
Fine sand =0.3-0.4
Sandy loam =0.4-0.6
Clayey loam=0.6-0.8
Clay =0.8-2.0
Stone masonry =0.8-2.0
Page: 34
Concrete = 1.0-3.0
b) Sectional profiles:
Semicircular
Rectangular
Triangular
Trapezoidal
c) Two parts of calculations for canal

Evaluation of the design based on the user specified parameters.
Optimum canal parameters computations based on the MHP Sourcebook by Allen R Iversin.
d) Two spreadsheets are included in the Design Aids for:

a. Canal calculations (Figure 5.1 for flow chart and Figure 5.3 for an illustrative example)
b. Pipe calculations (Figure 5.4 for flow chart and Figure 5.5 for an illustrative example).
The calculations presented in Figure 5.4 are briefly described in the following section. The rectangular
intake canal is considered for the illustration.
Present Canal:
2
Area A m = D*B
= 0.3*0.5
= 0.15 m2
Top Width T (m) = B+2*H*N

= 0.5+2*0.3*0
= 0.5m
Wetted Perimeter (m) = 2*D+B

= 2*0.3+.5
= 1.1m
Hydraulic Radius r (m) = A/P

= 0.15/1.1
= 0.136 m
3
Calculated flow (m /s) = A*r2/3*S0.5/n
= 0.15*0.1362/3*0.012990.5/n
= 0.226 m3/s
Critical Velocity Vc m/s = sqrt(A*g/T)

= sqrt(0.15*9.81/.5)
= 1.72 m/s
Velocity V m/s = Q/A

= 0.185/0.15
= 1.233 m (Okay since it is less than 80% of Vc)
Headloss hl (m) = S*L + di (drops)

= 0.01299*20+0
= 0.260m
Page: 35
Start
W etted perimeter (P)
Project name, Reach name, Semicircular = PI()* D/2
Design discharge (Qd) Trapezoidal = B+2*D*sqrt(1+N^2)
Roughness coefficient (n) Rectangular =2* D+B
Side slope (N) Triangular = 2*D*sqrt(1+N^2)
Sectional profile
Canal length (L)

1/canal slope (1/S) r = A/P, Qc = A*r^(2/3)*S^0.5/n
Canal depth/diameter (D) FB=min(0.3,0.5*D)
Freeboard (FB) V = Q/A, hl =S*L+di
Canal width (B) hl =hl previous + hl (continuous)
Desired velocity (Vo) d crit =11000*r*S
Canal drop di (V) & hi(H)
Flow area (A)

semicircular = PI()* D^2/4/2
Trapezoidal = (B+N*D)*D
Rectangular = D*B
Triangular = D*B/2
Ao = Qd/Vo,
T=B+2*D*N (trapezoidal) or =B
Vcrit = sqrt(9.81*Ao/T)
V desired=80% of Vcrit,
ro for optimum canal

Semicircular = 0.4*SQRT(A)
Trapezoidal=0.5*SQRT(Sin(N)*A/(2-COS(N))
Rectangular/Traingular = 0.35*SQRT(A)))
Depth Do for optimum canal

Semicircular = 4*ro
Traingular = 2.8*ro
Rectangular/Trapezoidal = 2*ro
Ho = Do + FBo
Channel width Bo
Semicircular = 2*Do hl =S*L+di
Rectangular = 4*ro Hl =hl previous + hl End
Traingular = 5.7*ro d crit =11000*r*S
Trapezoidal = 4*ro/Sin(N)
Figure 5.1: Flow chart for canal design
Critical dia of sediment d crit (mm) = 11000*r*S

= 11000*0.136*0.01299
= 19.48mm (i.e., it can self clean sediment of diameter 19.48 or less)
Optimum Canal:
2
Area A m = Q/v desired
= 0.185/1
= 0.185 m2
Page: 36
Hydraulic Radius ro (m) = 0.35*SQRT(A)

= 0.35*SQRT(0.185)
= 0.1505 m
Depth Do (m) = 2*ro

= 2*0.1505
= 0.301m
Top Width Bo (m) = 4*ro

= 4*0.1505
= 0.602m
Critical Velocity Vc m/s = sqrt(A*g/T)

= sqrt(0.185*9.81/.602)
= 1.74 m/s (Okay since the desired velocity of 1m/s is less than 80% of
Vc)
Headloss hl (m) = S*L + di (drops)

= 0.0050*20+0
= 0.100m
Critical dia of sediment d crit (mm) = 11000*r*S

= 11000*0.136*0.0050
= 8.271mm (i.e., it can self clean sediment of diameter 19.48 or less)
Chhota MHP
Stone masonry canal
Input
Type and Name Intake Canal Tailrace Main2 Main3
Flow (m3/s) 0.185 0.145 0.145 0.145
Roughness coefficient (n) 0.02
0.02 0.017
0.017 0.02
0.02 0.02
0.02
Sectional Profile Rectangular Trapezoidal Semicircular Triangular
Side slope N (1V:NHorizontal) 00 0.5
0.5 00 0.5
0.5
Length of the canal (m) 20 40 150 120
1/Canal slope (s) 77 200 30 72
Channel Depth/diameter D (m) 0.300 0.525 0.300 0.300
Freeboard FB (m) 0.300 0.250 0.150 0.150
Channel Width (B) m 0.500 1.000 0.400 0.400
Channel Drops di m 0.000 0.000 0.000 0.000
Channel Drops Horizontal length hi m 0.000 0.000 0.000 0.000
Desired velocity Vo (m/s) 1.000 1.500 1.500 1.500
Output
Side slope d (degrees) 0.000 63.435 0.000 63.435
Canal slope S 0.01299 0.00500 0.03333 0.01389
Total depth H (m) 0.600 0.775 0.450 0.450
Chainage L (m) 20.000 60.000 210.000 330.000
Page: 37
Present canal
Area A m2 0.150 0.663 0.035 0.060
Top Width T (m) 0.500 1.525 0.400 0.400
Wetted Perimeter P (m) 1.100 2.174 0.471 0.671
Hydraulic Radius r (m) 0.136 0.305 0.075 0.089
3
Calculated flow (m /s) 0.226 1.249 low 0.057 low 0.071
Comment on freeboard ok low ok ok
Velocity V m/s 1.233 0.219 4.103 2.417
Critical Velocity Vc m/s & Remarks 1.72 Ok 2.06 Ok 0.93 Not Ok 1.21 Not Ok
Headloss hl (m) 0.260 0.200 5.000 1.667
Total headloss Hl(m) 0.260 0.460 5.460 7.126
Critical dia of sediment d crit (mm) 19.481 16.769 27.500 13.665
Optimum canal
Area Ao m2 0.1850 0.0967 0.0967 0.0967
Top Width T (m) 0.6022 0.7636 0.9949 0.4867
Critical Velocity Vc m/s & Remarks 1.74 Ok 1.11 Not Ok 0.98 Not Ok 1.4 Not Ok
Hydraulic Radius ro (m) 0.1505 0.1180 0.1244 0.1088
Channel Depth/diameter Do (m) 0.301 0.236 0.497 0.218
Freeboard Fbo (m) 0.150 0.263 0.150 0.150
Total depth Ho (m) 0.451 0.498 0.647 0.368
Channel Width Bo (m) 0.602 0.528 0.995 0.487
Canal Slope 0.0050 0.0112 0.0145 0.0173
Headloss hlo (m) 0.100 0.449 2.175 2.079
Total headloss Hlo(m) 0.100 0.549 2.724 4.803
Critical dia of sediment d crito (mm) 8.271 14.584 19.834 20.736
Figure 5.2: An example of canal design.
B = 0.5 & 0.602
D = 0.6 & 0.451

d & FB (0.3 & 0.3)
& (0.301& 0.15)
B = 1& 0.764
D = 0.775 & 0.498

d & FB (0.525 &
0.25) & (0.236 &
0.263)
B = 0.4 & 0.995

D = 0.45 & 0.647
d & FB (0.3 & 0.15)

& (0.497 & 0.15)
B = 0.4 & 0.487

D = 0.45 & 0.368
Figure 5.3: Illustrated canal type and their dimensions.
Page: 38
5.3.2 Pipe
The headrace pipe calculations presented in Figure 5.7 are briefly described in the following section. The
trashrack calculations are similar to the trashrack calculations presented earlier in the intake design,
hence it is not presented in this section. In this example, one HDPE pipe is considered for a design flow of
160 l/s each.
Sizing of headrace pipe

Headloss
HDPE pipe roughness, k =0.06 mm
k 0.06 mm
= = 0.000231
d 260 mm
1.2Q 1.2 x0.160
= = 0.73846
d 0.260
From Moody chart (Appendix), f=0.0153. In the spreadsheet program, this friction factor is
calculated by the method described in Layman’s Guidebook on how to develop a small
hydro site, ESHA. In this method f is calculated by iterating following equations:
l V2
Friction loss = f
d 2g
fl 0.08Q 2 0.0153 x140 x0.08 x0.160 2
hwall loss = = = 3.82 m
d5 0.260 5
Turbulent losses considering, Kentrance= 0.8, Kexit=1.0 and Kbends based on the bending angles (see
Table in the Appendix)
æ 1.5V 2 ö 3.012
\ hturbulentlosses = (K entrance + K bends + K valve + K others + K exit )çç ÷÷ = 1.5 * = 0.69m
è 2g ø 2 x9.81
Total head loss = 3.82 m + 0.69 m = 4.53 m
Design water level in Gravel trap is 4.53 m (i.e. 22.66% of the available head) below low river level at
intake. This is a headrace pipe conveying water from intake to the break pressure tank, therefore
headloss more than this may be acceptable if the pipe material is mild steel. The HDPE pipe does not
need expansion joints and therefore not calculated.
Page: 39
Start
Project Hydraulics Pipe Trashrack Exp Joint

Name, Qd, Hg, RL us, #, Material, Fabrication Bar type, Tmax, Tinst,
Location, %hl, Entrance, If steel, Laying, Valve, t,b, Vo, Tmin, Group
Life Exit, R/d t, L, q(upto 10) F, b,H L (5)
Exp Joint Hydraulics Trashrack

Dimensions, Position hl(friction, turbulent) hl, Surface Area,
during installation Other criteria checking Width, h submerge
End
Figure 5.4: Flow chart for pipe design
INPUT
General:
Project: Chhyota MHP
Location: Dolakha Economic life (years) 15
Hydraulics:
Diversion flow Qd (m3/s) 0.110 U/S Invert Level (m) 1200.00
Flow in each pipe Qi (m3/s) 0.110 % head available or headloss hlt (m) 5.00%
Gross headHg (m) 5.000 Entrance Type Slightly rounded 0.2
Bending radius (r/d) 5 0.3
Headrace pipe
Pipe Material PVC Exit (Yes/No) Yes
Welded / Flat rolled if steel Welded No of pipes 1.00
Rolled if steel Rolled Bending angle 01 20.00
Type if steel IS Bending angle 02 4.00
Burried or exposed Burried Bending angle 03 6.00
Type of valve Gate 0.1 Bending angle 04 20.00
Non standard ultimate tensile strength (UTS) N/mm2 0 Bending angle 05 0
Estimated pipe diameter d(mm) 245 Bending angle 06 0.00
Provided pipe diameter d(mm) 400 Bending angle 07
Min pipe thickness t (mm) NA Bending angle 08
Provided pipe thickness t (mm) 3.0 Bending angle 09
Pipe Length L (m) 100.000 Bending angle 10
Trashrack
Flat k t b Vo f b Q H
2.40 6.00 20.00 1.00 60.00 0.00 0.110 3.00
Expansion Joints
Tmax (deg) T installation Tmin 1st Pipe length(m) 2nd Pipe L (m) 3rd Pipe L (m) 4th Pipe L (m) 5th Pipe L (m)
40 20 4 50.00 100.00 150.00 200.00 250.00
Page: 40
OUTPUT
Trashrack
hf hb H coeff H S B Min Submergence CGL=1.5v^2/2g
0.0213 0.0000 0.4174 0.0213 0.5504 0.16 0.81 0.06
Turbulent loss coefficients

K inlet 0.20 K bend 05 0.00 K bend 10 0.00
K bend 01 0.16 K bend 06 0.00 K valve 0.10
K bend 02 0.13 K bend 07 0.00 K exit 1.00
K bend 03 0.13 K bend 08 0.00 K others
K bend 04 0.16 K bend 09 0.00 K Total 1.71
Hydraulics
Pipe Area A (m2) 0.126 U/S Invert Level (mAOD) 1200.000
Hydraulic Radius R (m) 0.10 D/S Invert Level (mAOD) 1195.000
Velocity V (m/s) 0.88 Is HL tot < HL available OKAY
Relative Roughness ks/d 2.500E-05 Friction Losses hf (m) 0.14
Reynolds Number Re = d V /Vk 307018 Fitting Losses hfit (m) 0.07
Type of Flow Turbulent Trashracks and intake loss (m) 0.02
Friction Factor f 0.0147 Total Head Loss htot individual (m) 0.23
% of H.Loss of individual pipe 4.62% Ok
Expansion Joints (mm) Coeff of linear expansion /deg C 5.4E-05
EJ number 1 2 2 4 5
dL theoretical 97 194 292 389 486
dL recommended 194 389 583 778 972
dL for expansion 108 216 324 432 540
dL for contraction 86 173 259 346 432
Figure 5.5: An example of pipe design
Page: 41
6 SETTLING BASINS
6.1.1 Sediment Settling Basins

A settling basin traps/removes sediment (sand/silt) from water. Since sediment is detrimental to the
project civil and mechanical structures and elements, the specific size of the sediment has to be removed
to specified percentage. This can only be achieved by reducing turbulence of the sediment carrying
water. The turbulence can be reduced by the construction of settling basins along the conveyance
system. Since the settling basins are straight and have bigger flow areas, the transit velocity and
turbulence are significantly reduced allowing the desired sediments to settle. The sediment thus settled
has to be properly flushed back to the natural rivers.
Thus a settling basin:

1. Prevents blocking of headrace and reducing capacity
2. Prevents severe wearing of turbine runner and other parts.
3. Reduces the rate failure and O&M costs.
According to the location and function the settling basin can be of following types:
1. Gravel Trap for settling particles of 2mm diameter or bigger.
2. Settling Basin for settling particles of 0.2mm diameter or bigger.
3. Forebay for settling similar to settling basin (optional) and smooth flow transition from open to
closed flow.
Micro hydro settling basins are generally made of stone masonry or concrete with necessary accessories
such as spillways, flushing gates, trashracks, etc., as and where necessary. However, functionally, all the
settling basins should have following components:
1. Inlet Zone: Gradual expansion.
2. Settling Zone: Settling, deposition, spilling and flushing (and trashrack removal).
3. Outlet Zone: Gradual contraction.
A typical section of a settling basin with all the components (inlet, transition, storage and outlet zones) and
accessories (spillway, gate) is presented in Figure 6.1.
Figure 6.1: Typical section of a settling basin
Page: 42
6.2 SETTLING BASIN THEORY

An ideal settling basin is a basin where the flow is ideal and it flows in a straight line (no turbulence, no
eddy current). In practical not a single basin is ideal. For an ideal basin shown in figure 6.3:
a) H/W = L/V => Q/W = L*B = Surface area (i.e., the surface area is directly proportional to
the discharge and inversely proportional to the settling velocity/sediment
diameter/temperature).
Figure 6.3: An ideal setting basin
As stated earlier a real basin is never ideal and the efficiency of an ideal basin is generally 2 times higher
than that of a real basin. This is mainly because of the following factors:
1. Presence of water turbulence in basin.
2. Imperfect flow distribution at entrance.
3. Flow convergence towards exit.
Vetter’s Equation takes care of the factors stated above and hence recommended for use in settling basin
design.
6.3.1 Gravel Trap

While designing gravel trap, AEPC has outlined following points:
1. Location: Close to intake and safe.
2. Dimensions: Sufficient to settle and flush gravel passing through upstream coarse trashrack.
3. Spilling: Sufficient spillway/vertical flushing pipe.
4. Spilling and flushing: back to the river.
5. Material: 1:4 cement stone masonry with 12mm thick 1:2 cement plastering on the waterside.
6. Recommended settling diameter and trap efficiency are 2mm and 90% respectively.
7. Sediment storage zone: Storage for 12 hours (flushing interval)
8. Drawdown: Capacity of drawdown discharge = 150% of the design discharge.
9. Aspect ratio (straight length to width): 1.5 to 2.
Page: 43
6.3.2 Settling Basin

While designing a settling basin, AEPC has outlined following points:
1. Location: Close to gravel trap/Intake.
2. Dimensions: Sufficient to settle and flush the designed sediment size.
3. Spilling: Sufficient spillway/vertical flushing pipe (layout dependent).
4. Spilling and flushing: back to the river.
5. Material: 1:4 cement stone masonry with 12mm thick 1:2 plastering on the waterside.
6. Recommended settling diameter (trap efficiency) and head
a. 0.3-0.5mm (90%) – 10m
b. 0.3mm (90%) ------- 10 to 100m
c. 0.2mm (95%) -------- more than 100m
7. Sediment storage zone: Storage for 12 hours (flushing interval)
8. Drawdown: Capacity of drawdown discharge = 150% of the design discharge.
9. Aspect ratio (straight length to width): 4 to 10.
6.3.3 Forebay
While designing forebay, AEPC has outlined following points:
1. Dimensions and functions: Similar to SB if u/s is open canal or combined SB+FB.
2. Submergence: Sufficient to prevent vortex (ie 1.5 * v2/2g).
3. Active Storage: 15 sec * Qd.
4. Freeboard: 300mm or half the water depth whichever is less.
5. Drawdown: A drain pipe/Gate.
6. Spilling capacity: Minimum of spilling Qd (load rejection)
7. Fine Trashrack:
a. At the entrance of the penstock
b. Inclination: 3V:1H
c. Bars: Placed along vertical direction (ease of racking).
d. Clearance: 0.5 * nozzle diameter (Pelton) or half the distance between runner blade
(Crossflow)
e. Velocity: 0.6 to 1m/s
f. Weight: =< 60kg (porter load)
6.4 PROGRAM BRIEFING AND EXAMPLES

6.4.1 Features of the spreadsheet
1. A single spreadsheet for:
a. Gravel Trap
b. Settling Basin (Desilting)
c. Forebay-cum-Settling Basin
2. Settling of sediment using:
a. Ideal settling equation
Page: 44
b. Vetter’s equation
3. Flushing of deposited sediment during:
a. Normal operational hour
b. Drawn-down condition
4. Sediment flushing with:
a. Vertical flushing pipe
b. Gate
c. Combination of both
5. Spilling of excess flow due to:
a. Incoming flood
b. Load rejection
6. Spilling of excess flow with
a. Spillway
b. Vertical flushing pipe
c. Combination of both
7. Drawdown / Dewatering with:
a. Vertical flushing pipe
b. Gate
8. Rating curve for the gate: The rating curve computation is based on Norwegian Rules and
Regulations of Dam Construction. According to this manual, the flow is of free flow until the gate
opening is two third of the water depth behind the gate. Beyond this level (i.e., the gate opening
hither than 2/3 of the water depth behind the gate), the flow is a pressure flow.
9. Multiple basins
10. Combination of approach canal / pipe options
6.4.2 Vertical flushing pipe

1. Overflow: Acts as a sharp crested weir.
Qf =p*d1*Cw*hf 2/3: Cw = 1.6
d1 = Qf/(1.6*p*hf2/3)
2. Drawdown / Dewatering
1.5*Qd =C*A*(hb+fflush) 0.5: A=p*d212/4: C=2.76 for L=<6m
d21=(6*Qd/( p *C *( hb+fflush)0.5 )0.5 @ full
d22=(4*Qd/( p *C *( fflush)0.5 )0.5 @ empty
3. Design diameter: Maximum of above (d1, d21,d22)
6.4.3 Spillway at intake

hovertop = 50% of (FB – spillway crest height above NWL)
Ls1 =Qf/C/hovertop1.5:=>obstruction d/s=> hot is constant
Ls2 =2*Abs(Qf-Qd)/C/ hovertop 1.5)
Ls3=Qf/C/(2* hovertop -0.05)1.5:=>obstruction d/s=> (100%-0.05) hot is constant
6.4.4 Gate
Lifting force F(kg)=W buoyant + 1000*m*Asub*hcg
Gate opening dh=h1-h2
Page: 45
dh<2/3*h1 :=> Pressure flow (as a gate): Q=C*L*(H11.5-H21.5)

dh=>2/3*h1 :=> Open flow (as a spillway ): Q=C*L*H11.5
Enter the maximum gate opening in the lowest gate opening cell and press the Calculate Gate
Rating Curve button for computing rating curve.
Figure 6.4: Flushing pipe details
Setlling Basin Design by Vetter's Equation

Chhota MHP
Q flood 0.000 Sediment swelling factor S = 1.50

Manning's number M (m1/3/s) 1/n= 50.000 Volume of sediment storage V (m3) = 15.12
Design discharge Qdesign (m3/s) = 0.421 Sediment depth Hs (m) = V/Asi 0.60
Flushing discharge Qf lush (m3/s) = 0.034 Inlet approach conveyance Canal/Pipe = Canal
Total discharge Qbasins (m3/s) = 0.455 1/Bottom slope of SB Sf (1:50 to 1:20) = 50.00
Particles to settle d (mm) = 0.300 Outlet approach conveyance Canal/Pipe = Pipe
Trapping efficiency n (%) = 85% Water level at inlet NWL (m) = 1950.00
water temperature t (oC) = 10 h flush below the base slab (L<6m) 1.70
Fall velocity w at 10 deg C (m/s) = 0.035 Number of basins N 1.00
Sediment concentration Cmax (kg/m3) = 2 Spillway crest height above NWL m 0.05
Flushing Frequency FI (hours) = 8 Spillway discharge coeff 1.60
Surface area / basin Asi (m2) 85 % = 25.000 Provided Freeboard h fb1 m 0.30
Basin transit velocity Vt (m/s) = 0.241 Discharge coeff for pipe as orifice (2.76 if L <6 m) 2.76
Bulk Sed density G (kg/m3) = 2600 Drawdown discharge % of design discharge 1.00
Discharge per basin Qbasin (m3/s) = 0.455 Water depth of inlet canal hc1 (m) = 0.50
Max section width for hydraulic flushing B (m) = 3.258 Outlet canal width /canal diameter Bc2 (m) = 0.50
Width used B (m) = 2.500 Water depth of outlet canal hc2 (m) = 0.30
Inlet canal width /canal diameter Bc1 (m) = 1.000 Provided Length of the basin Lact (m)= 0.00
Page: 46
Length of basin L (m) = 10.000 Pipe does not need a straight approach! ***
Aspect ratio (4<=AR<=15) 4.000 Head over outlet weir h overtop (m) = 0.23
Min. water depth Hi (m) = 0.755 Approach inlet velocity vi1 (m/s) = 0.91
X-sectional area / basin Ai (m2) = 1.888 Approach outlet velocity vi2 (m/s) = 3.03
Wetted perimeter / basin Pi (m) = 4.010 1/Energy gradient during operation So = 15763.86
Hydraulic radius Ri (m) = 0.471 d 50 during operation (mm) = 0.33
Normal WL @ basin h b m = 1.360 Depth of water during flushing yfi (m) = 0.12
Straight inlet transition length at 1:5 (m) = 3.750 d 50f during flushing (mm) = 49.32
Straight approach canal length (m) = 10.000 Length of an Ideal Basin (m) = 10.00
Spilling of excess water

Vertical Flushing pipe
Diameter for flood d1 m = 0.000 Diameter for load rejection (u/s flood bypass) d1 m = 2 x 0.43
Spillway
Freeboard m 0.300 Spillway length for Qd (under operation) 6.43
Spillway overtopping height h overtop m 0.125 Spillway length for Qd (load rejection & u/s flood bypass) 6.43
Spillway length for Qf (flood and non operational) 0.000 Spillway length for Qd (d/s obstruction & full hovertop-50) 3.18
Combination of vertical flushing pipe and spillway Flood and non operational (Qf)
Vertical flushing pipe diameter d1 m 0.30 Flood discharge passing through vertical pipe 0.000
No of vertical flushing pipe 1.00 Spillway length for the remaining discharge m 1.00
Spillway length used (m) 1.00
Flood and Under Operation (Qf- Qd) Load Rejection (Qd)

H overtopping 0.00 H overtopping 0.262
Discharge passing through vertical pipe 0.00 Discharge passing through vertical pipe 0.240
Discharge passing over spillway 0.00 Discharge passing over spillway 0.215
Figure 6.5: Typical example of a settling basin (Settling basin, spilling and flushing).
Calculate Gate Rating Curves

Flushing of water and sediment
Flushing pipe and orifice diameter Gate Relative Discharge
d for incoming flow and draw down m 0.35 Opening Gate Openinig One basin
d for incoming flow only (empty state) m 0.40 Hg Hg/H1 Q
d for incoming flow only (empty state & with y flushing) m 0.39 0.000 0.000 0.000
0.033 0.025 0.127
Gate 0.067 0.049 0.249
Buoyance weight of the gate W kgf 300.00 0.100 0.074 0.366
Gate Opening B, (m) 1.00 0.133 0.098 0.479
Gate Opening H (m) 0.50 0.167 0.123 0.591
Submerged area of th gate A m2 0.50 0.200 0.147 0.700
Water surface to cg of submerged area h m 1.11 0.233 0.172 0.807
Coeff of static friction mu 0.90 0.267 0.196 0.912
Lifting force F kgf 799.50 0.300 0.221 1.016
H. of water (H1) 1.36 0.333 0.245 1.117
0.367 0.270 1.216
0.400 0.294 1.312
0.433 0.319 1.406
0.467 0.343 1.497
0.500 0.368 1.586
Figure 6.6: Typical example of a settling basin (Gate and rating curve).
Page: 47
Forebay cum settling basin (for one basin only)

Penstock diameter m 0.41
Penstock velocity m/s 3.45
Submergence depth of penstock pipe m 0.91
Height of pipe above the base slab m 0.30
Min. pond depth m 1.62
Effective thickness of penstock mm 3
FS for air vent (5 burried, 10 exposed) 10
Young's modulus of elasticity E N/mm2 200000
Penstock inlet gate (Yes/No) No
Air vent diameter mm Nominal
Gradual Expansion of 1:5 half of Gr expansion
0.500
0.500 2.5 Flushing cone/spillw ay O
Gradual Expansion 1 in 10 (1:2 for MHP) L =10

Spillw ay 0.300
0.300 Water depth 0.76
Sediment depth 0.605 Slope 1:50
Figure 6.7: Typical example of a settling basin (forebay and dimensioning).
The headrace pipe calculations presented in Figure 6.6 are briefly described in the following section.
Sizing of settling basin

1. Settling of sediment using:
a. Vetter’s equation
Surface area of basin = -(Qtotal)/w*LN(1-neff)
Asi = -(0.455)/.035* LN(1-neff)
2
= 25 m
Max section with for hydraulic flusing = 4.83*Q^0.5

= 4.83*.455^0.5
= 3.258m
Provided Width B = 2.5m
Length of basin L = Asi/B

= 25/2.5
= 10m, which is 4 times the witdth hence, satisfies the requirement.
Basin transit velocity vt = 0.44* sqrt(d)

= 0.44*sqrt(0.2)
= 0.241m/s
Water depth Hi = Qi/B/vt

= 0.455/2.5/0.241
= 0.755m
Sediment storage volume assuming 100% trap efficiency (conservative side)

V = (Qtotal)*(Flusing intensity in sec)*Concentration max in kg/Bulk Sed. Densigy in
3
kg/m /Sed Swelling factor
= (Qtotal)*(FI*3600)*Cmax/G*S
= 0.455*(8*3600)*2/2.6*1.5
3
= 15.12m
Sediment depth Hs = V/Asi

= 15.12/25
= 0.6m
Page: 48
b. Ideal settling equation
Length of an Ideal Basin= Maximum of (4xB and Q/B/w)

= MAX(4*2.5, 0.455/2.5/0.035)
= MAX(10, 5.2)
= 10 m
2. Spilling of excess flow due to load rejection: A combination of a 0.3m diameter vertical pipe and
spillway of 1.0m length is used.
H overtopping = h ot =(Q1/(1.9*PI()*n1*d1+Cd*Ls))^(2/3)
= (0.455/(1.9*pi()*1*.3+1.6*1))^(2/3)
= 0.262 m
Q pipe = 1.9*PI()*n1*d1*h ot ^1.5

= 1.9*pi()*1*.3*0.262^1.5
3
= 0.240 m /s
Q spillway = Cd*Ls*h ot ^1.5

= 1.6*1*0.262^1.5
3
= 0.215 m /s
3. Flushing of deposited sediment through the flushing pipe: The pipe diameter will be the biggest of :
a. For incoming flow and draw down:

D1 = (Qflushing%*4*Qi/(PI()*Cd*SQRT(h NWL+h flush)))^0.5
= (100%*4*0.455/(pi()**2.76*SQRT(1.36+1.7)))^0.5
= 0.35m
b. For incoming flow only:

D2 = (4*Qi/(PI()*Cd*SQRT(h flush)))^0.5
= (4*0.455/(pi()**2.76*SQRT(1.7)))^0.5
= 0.4m
In the second case the depth of water during flushing yfi may be added to h flush for higher precision.
This is not considered here. The recommended minimum diameter of the flushing pipe diameter is 0.4 m.
The gate curve in the example presented in Figure 6.6 includes the gate dimensions, forces and the rating
curve. The rating curve of the gate versus different gate opening can be computed by entering the
allowable gate opening at the lowest input cell and clicking “Calculate Gate Rating Curve” button.
The last part the spreadsheet can be used if the considered basin is a settling basin cum forebay. The
basic penstock inlet geometry is computed in this section.
Page: 49
7 PENSTOCK AND POWER CALCULATIONS

A penstock pipe conveys water from free flow (at a settling basin or a forebay) to pressure flow to
powerhouse and converts the potential energy of the flow at the settling basin or forebay to kinetic energy
at the turbine.
1. Material: Mild steel (exposed and buried) and HDPE (buried) pipes are widely used as penstocks for
micro hydro schemes in Nepal.
2. For exposed (i.e., above ground) mild steel penstock alignment, a minimum clearance of 300 mm
between the pipe and the ground should be provided for maintenance and to minimise corrosion
effects.
3. In case of buried HDPE pipes, they should be buried to a minimum depth of 1 m. Similarly, if mild steel
penstock pipes have to be buried, a minimum of 1 m burial depth should be maintained and corrosion
protection measures such as high quality bituminous/epoxy paints should be applied. Due to higher
risks of leakage, flange connected penstocks are not recommended to be buried.
4. The recommended initial trail internal diameter (D) can be calculated as:
D = 41 x Q 0.38 mm
Where, Q = Design flow in l/s
5. Total penstock headloss should be limited to 10% of the penstock gross head.
6. Anchor / Thrust block at every horizontal and vertical bends and for every 30m of straight pipe stretch.
7. Expansion joints should be placed immediately downstream of every anchor block for exposed mild
steel penstock.
8. Mechanical coupling of last penstock upstream of the turbine is recommended for ease of
maintenance and lesser force distribution to the turbine casing..
7.3 PROGRAM BRIEFING AND EXAMPLE

7.3.1 Program Briefing
The design procedure of the penstock is similar to that of the headrace pipes. In this spreadsheet, the
penstock is checked against surge / water hammer head propagated due to various closures of the
system. Sudden closure of one jet is considered in the calculations.
Power based on the AEPC criteria and actual power generation based on the actual cumulative efficiency
of the electro-mechanical are also presented.
Since a provision of maximum of ten bends is generally sufficient for a typical micro hydropower scheme,
ten bends are incorporated. However, users can add any cumulative values if there are more than ten
bends or other losses due to turbulence in the “K others” cells.
A fine trashrack is always recommended upstream of penstock inlet. A trashrack calculation is also
included with the minimum submergence criteria by Gordon and AEPC criteria. AEPC criterion of 150% of
the velocity head is enough for micro hydropower project up to 100kW.
User specific factor of safety and ultimate tensile strength are allowed in the spreadsheet.
Page: 50
The friction factor calculation is based on the iteration procedures described in the Layman’s Guidebook
on how to develop a small hydro site by European Small Hydropower Association.
Design and installation criteria of expansion joints are presented at the end of the spreadsheet.
Start
Project Hydraulics Pipe Trashrack Exp Joint

Name, Qd, Hg, RL us, #, Material, Fabrication Bar type, Tmax, Tinst,
Location, %hl, Entrance, If steel,Laying, Valve, t,b, Vo, Tmin, Group
Life Exit, R/d t, L, q(upto 10) F, b,H L (5)
Exp Joint Power Hydraulics Trashrack

Dimensions, Position Pturbine,P MGSP, hl(friction, turbulent) hl, Surface Area,
during installation P hnetPCU M Other criteria checking Width, h submerge
End
Figure 7.1: Flow diagram of penstock design
7.3.2 Typical example of penstock pipe

Figure 7.1 presents the calculation procedures applied in the example presented in Figures 7.2 and 7.3. A
two-nozzle Pelton turbine is selected for the given head and discharge. Since the trashrack and pipe
hydraulics are similar to headrace pipe presented earlier, they are not repeated in this section. The steel
pipe thickness, expansion joints and power calculations are presented in this section.
Pipe thickness:
It is worth noting that in reality the diameter of penstock pipe is optimized by calculating marginal
costs and benefit method. In this method, the incremental cost of annual energy by increasing the
pipe diameters and corresponding increase of costs are plotted. The intersecting point reflects the
cost of optimum diameter. Alternatively, net present values of these cash/cost flow can be
calculated and the net present value (NPV) of marginal benefit from energy gain should be higher
than that of the marginal cost of that diameter.
Let’s consider 4mm thick 300mm diameter pipe, the wave velocity
1440 1440
a= = = 1071.454 m / s
æ 2.1 x10 9 x d ö æ ö
1 + çç ÷÷ ç 2.1 x 10 9 x 0.300 ÷
è E xt ø 1+ ç ÷
ç 9 4 ÷
ç 200 x 10 x ÷
è 1000 ø
hsurge = a * V/(g*njet)
= 1071.454*2.12/(9.81*2)
= 115.84m
htotal = hgross + hsurge
Page: 51
= 69+115.84
= 184.84 m
t effective = t/(welding factor*rolling) – corrosion factor

= 4/(1.1*1.2) – 1.0
= 2.03mm
Factor of safety (allowable FS = 3.0)

t effective x S (2.03 1000) x 420 x10 6
S .F . = =
5 x htotal x 10 3 x d 5 x 184.84 x 10 3 x 0.300
= 3.0 which does not exceed the allowable FS of 3.0, hence OK
Based on the American Society of Mechanical Engineers (ASME) formula, the allowable thickness
is 4.00 mm. The static head for 3mm thick penstock of same diameter can be calculated by similar
procedures and found to be 57.91m. This can be found by decreasing the pipe thickness (and
diameter too) and noting the value corresponding to “H static capacity of the specified pipe (m)”.
The lower portion of the pipe corresponding to the static head of 69-57.91 = 11.09 m should be of
4mm thick 300 diameter pipe. The summary of the output is presented in Figure 7.3.
PENSTOCK AND POWER CALCULATIONS
INPUT
General:
Project: Gothi MHP
Location: Gothi Village, Gothi VDC, Humla Economic life (years) 15
Hydraulics:
Diversion flow Qd (m3/s) 0.150 WL @ forebay or U/S Invert Level (m) 1920.00
Flow in each pipe Qi (m3/s) 0.150 % head headloss hlt (m) 16.00%
Gross head (from forebay) Hg (m) 69.00 Cumulative knowm efficiency (g,t,tr,others) 79.38%
Power:
Turbine type (CROSSFLOW/PELTON) Pelton Valves (Sperical/Gate/Butterfly) Butterfly 0.3
No of total jets (nj) 2 Taper (Yes/No) No
Direct Coupling (Yes/No) No Exit (Yes/No) No
Closure time T sec 30 Non standard ult. tensile strength (UTS) N/mm2 0
Number of units 1
Penstock pipe:
Pipe Material (STEEL/HDPE/PVC) Steel Safety factor for lower pipes (0 for default) 3
Welded / Flat rolled if steel Welded Entrance Type Slightly rounded0.2
Rolled if steel Rolled Entrance with gate and air-vent (Yes/No) No
Type if steel (UNGRAGED/IS) IS Bending radius (r/d) (1/2/3/5/1.5) 1.5 0.45
Burried or exposed Exposed Bending angle 05 22
No of pipes 1.00 Bending angle 06 14.00
Bending angle 01(degrees) 27.00 Bending angle 07 38.00
Bending angle 02 11.00 Bending angle 08 22.00
Penstock diameter d=>d estd, d act (mm) 275 300 Pipe thickness t=>t min, t act (mm) 3.0 4.0
Pipe Length L (m) 121.000 Roughness coefficient (ks) 0.060
Trashrack
k t b Vo f b Q H
0.00 6.00 20.00 1.00 71.56 0.00 0.150 0.70
Expansion Joints
Tmax (deg) T installation Tmin 1st Pipe length(m) 2nd Pipe L (m) 3rd Pipe L (m) 4th Pipe L (m) 5th Pipe L (m)
40 20 4 10.00 15.00 20.00 25.00 30.00
Figure 7.2: Input required for penstock and power calculations
Page: 52
OUTPUT
Trashrack
hf hb H coeff H S B Min Subm ergence CGL=1.5v^2/2g
0.0000 0.0000 0.0000 0.0000 0.6852 0.93 1.15 0.34
Turbulent loss coefficients K Total 2.82

K inlet 0.20 K bend 05 0.24 K bend 10 0.33
K bend 01 0.26 K bend 06 0.22 K valve 0.30
K bend 02 0.21 K bend 07 0.29 K taper 0.00
K bend 03 0.19 K bend 08 0.24 K exit 0.00
K bend 04 0.21 K bend 09 0.32 K others
Hydraulics
Pipe Area A (m 2) 0.071 U/S Invert Level (mAOD) 1920.00
Hydraulic Radius R (m) 0.08 D/S Invert Level (mAOD) 1851.00
Velocity V (m/s) 2.12 Is HLtot < HL available OKAY
Pipe Roughness ks (mm) 0.060 Friction Losses hf (m) 1.41
Relative Roughness ks/d 2.000E-04 Fitting Losses hfit (m) 0.65
Reynolds Number Re = d V /Vk 558214 Trashracks and intake loss (m) 0.00
Type of Flow Turbulent Total Head Loss htot individual (m) 2.06
Friction Factor f 0.0153 % of H.Loss of individual pipe 2.99% Ok
Factor of Safety
Young's modulus of elasticity E N/mm 2 200000 Ultimate tensile strength (UTS) N/mm2 410
Thickness 4.000 H total for one jet closure of Pelton(m) 184.84
Diameter (mm) 300.000 t effective (mm) 2.03
Net Head (m) 66.940 Minimum t effictive for negative pressure (mm) 3.14
Wave Velocity a (m/s) 1071.454 Comment on thickness NA, No gate
Critical time Tc (sec) *2 = Closing time T 0.23 Ok Safety Factor (S) 3.00
K if crossflow turbine Kcf 0.00000 Check on Safety Factor Ok
Hsurge for one jet closure of Pelton(m) 115.840 Air vent diameter d vent (mm) 43.65
Hsurge for instanteneous closure of all unit closure of Pelton (m) 231.680 H total capacity of the specified pipe (m) 184.98
Lengths (max & actual) of the specified pipe (m) & Ok 155.120 121.000 H static capacity of the specified pipe (m) 88.46
Power
Turbine efficiency as per MGSP 75.00% Electrical Power as per MGSP GL (kW) 50.77
Available shaft power(kW) 70.18 Electrical Power based on Hnet (kW) 59.10
Reqd.'Turbine Capacity (+10%) (kW) 77.20 Power for known cumulative eff (kW) 78.19
Expansion Joints (mm) Coeff of linear expansion /deg C 1.2E-05

EJ number 1 2 2 4 5
dL theoretical 4 6 9 11 13
dL recommended 9 13 17 22 26
dL for expansion 5 7 10 12 14
dL for contraction 4 6 8 10 12
Figure 7.3: Output of penstock and power calculation spreadsheet.
Page: 53
8 TURBINE SELECTION
A turbine converts potential energy of water to rotational mechanical energy. Cross-flow and Pelton
turbines are the most commonly used turbines in Nepali micro hydropower plants. The size and type of
turbine for a particular site depends on the net head and the design flow. Pelton turbines are suitable
where the ratio of head to flow is high whereas Cross-flow turbines are suitable for high flow and low head
schemes. It should be noted that for certain head and flow ranges both Pelton (multi-jet) and Cross-flow
turbines may be appropriate. In such cases, the designer should consult with the manufacturer and make
a decision based on availability, efficiency and costs. On a horizontal shaft Pelton turbine the maximum
number of jets should be limited to 3 for ease of manufacturing. The number of jets can be higher for
vertical shaft Pelton turbines. However, these require higher precision work in mounting the generator
vertically on the turbine shaft and furthermore, in case of varying rotational speeds (RPM of the turbine
and the generator), the belt drive arrangements (including those for mechanically coupled end uses) will
be difficult.
Figure 8.1: A Pelton and a Crossflow Turbines

The recommended net heads for maximum rpm and efficiencies for different turbines and turbine
specifications are presented in Table 8.1.
Table 8.1: Turbine specifications

Type Net head (m) Max RPM Efficiency (nt)
Pelton More than 10m 400 to 1500 70 - 75%
T12 Crossflow up to 50m 900 60 - 78%
T15 Crossflow up to 80m 1500 60 - 78%
The type of turbine can be determined by its specific speed given by the following equation:
Sp Speed (no gear) ns = rpm*√(1.4*P kW/N tur)/Hn5/4
Sp Speed (gear) nsg = Sp Speed (no gear)* Gear at Turbine/Gear at Generator
The only unknown in the above equation is the turbine rotational speed (N). This depends on the RPM of
the generator and the drive system used (e.g., direct or belt drive). The specific speed of a multi-jet Pelton
turbine can be computed by multiplying the above ns by the square root of the number of jets. Because of
higher efficiency both in overall and part load, preference should be given to Pelton turbines. If ns exceeds
the range given in Table 8.2, multiple units should be used.
Page: 54
Table 8.2: Turbine type vs. ns

Turbine types ns Ranges
Single Jet Pelton 10 – 30
Double Jet Pelton 30 – 40
Three Jet Pelton 40 – 50
Cross flow 20 – 80

The Turbine spreadsheet is presented in Figure 8.2. The specific speeds (ns) with and without gear are
calculated as:
Sp Speed (no gear)= rpm*SQRT(1.4*P kW/N tur)/Hn^(5/4)

= 750*SQRT(1.4*67.89/1)/58^(5/4)
= 46 (Turgo/Crossflow/2-jet Pelton is suitable)
Sp Speed (gear) = Sp Speed (no gear)* Gear at Turbine/Gear at Generator

= 46*1/2
= 23 (Single jet Pelton/Crossflow is suitable)
Specific speed of multi-jet Pelton is computed by multiplying the specific speed of runner by the
square root of the number of the jets. The calculations show that for the given parameters in the
context of micro hydro plants in Nepal, either a gearless Crossflow turbine or a Pelton/Crossflow
with a gear ratio of 1:2 is recommended.
Turbine Selection
Chhota MHP
Input
Discharge (l/s) 150 Gear ratio at turbine 1
Gross head (m) 69 Gear ratio at generator 2
Hydraulic losses 15.94% No of turbines/generators 1
Max turbine output kW 67.89 Total number of jets if Pelton n 2
Turbine rpm 750
Output
Net head m 58.000 Generator with gearing rpm 1500
No Gearing With Gearing

Sp speed of runner rpm (no gearing) 46 Sp speed of turbine 23
Pelton (12-30) => (Ns 17-42) ** Pelton (12-30) => (Ns 17-42) Pelton
Turgo (Ns 20-70) => (Ns 28-99) Turgo Turgo (Ns 20-70) => (Ns 28-99) **
Crossflow (Ns 20-80) Crossflow Crossflow (Ns 20-80) Crossflow
Fracis (Ns 80-400) ** Fracis (Ns 80-400) **
Propeller or Kaplan (Ns 340-1000) ** Propeller or Kaplan (Ns 340-1000) **
Figure 8.2: A Typical turbine example.
Page: 55
9 ELECTRICAL EQUIPMENT SELECTION

A generator converts mechanical energy to electrical energy. There are two types of generators; namely,
synchronous and induction (asynchronous). Induction generators are inexpensive and appropriate for
small schemes (up to 15kW). For large schemes (10kW and more), the synchronous generators are
suitable. Both synchronous and asynchronous generators are available in single and three phases.
Load controllers are generally used as the governing system in Nepali micro hydro schemes. An
Electronic Load Controller (ELC) is used for controlling the power output of a synchronous generator. To
control an induction generator an Induction Generator Controller (IGC) is used.

9.2.1 Selection of generator size and type
Single Phase Vs. Three Phase

Advantages of Three Phase
· Saving of conductor and machine costs.
· Cheaper above 5 kW.
· Less Weight/size ratio.
Advantage of Single Phase

· Simple wiring.
· Cheaper ELC.
· Load balance not considered.
Induction Vs. Synchronous Generators

Induction Generator
Advantages of Induction Generator:
· Availability
· Cheap, rugged and simple in construction
· Minimum Maintenance
Drawbacks of Induction Generator:

· Problem supplying large inductive loads.
· Less durability of the capacitor bank.
· Poor voltage regulation compared to synchronous generator.
Synchronous Generator
Advantages of Synchronous Generator:
· High quality electrical output.
· Higher efficiency.
· Can start larger motors.
Drawbacks of Synchronous Generator:

· The cost is higher than induction generator for small sizes.
Based on the above assumptions, the general guidelines for selection of phase and type of generator are
prepared and summarized in Table 9.1.
Page: 56
Table 9.1: Selection of generator type

Size of scheme Up to 10 kW 10 to 15 kW More than 15 kW
Generator Synchronous/Induction Synchronous/Induction Synchronous
Phase Single or Three Phase Three Phase Three Phase
Factors affecting the size of the generator are temperature, altitude, electronic load controller correction
factor and power factor of the load. De-rating coefficients to allow for the above-mentioned factors are
presented in the Table 9.2.
Table 9.2: Generator rating factors
Max. Ambient
20 25 30 35 40 45 50 55
temperature in oC
A Temperature Factor 1.10 1.08 1.06 1.03 1.00 0.96 0.92 0.88
Altitudes 1000 1250 1500 1750 2000 2250 2500 2750

B Altitude Factor 1.00 0.98 0.96 0.945 0.93 0.915 0.90 0.88
Altitudes 3000 3250 3500 3750 4000 4250 4500
B Altitude Factor 0.86 0.845 0.83 0.815 0.8 0.785 0.77
C ELC Correction Factor 0.83
D Power Factor When load is light bulbs only 1.0

When load includes tube light and other inductive
0.8
loads
9.2.2 Sizing and RPM of Synchronous Generator:

The steps for selecting the size of a synchronous generator are as follows:
1 Take a power factor of 0.8.

2 The size of synchronous generator:
Installed Capacity in kW
Generator kVA = 1.3*-----------------------------
AxBxCxD
Where, A, B, C and D are correction factors from Table 9.2, and 1.3 is the overrating factor (up to
30% recommended) to allow for:
i) Unexpected higher power from turbine.
ii) Handling the starting current if large motors (> 10% of generator size) are supplied from the
generator.
iii) The generator running at full load when using an ELC.
3 The synchronous rotational speed:
120 f
Rotational speed ( N ) = RPM
P
Where, RPM is revolutions per minute
f is the frequency of the system in Hertz (Hz) (50 Hz in Asia and Europe)
P is the number of poles of the generator (2, 4, 6, etc., in pairs). P for Nepali MHP is
generally 4 so that the rotational speed is 1500 RPM.
Page: 57
9.2.3 Sizing and RPM of Induction Generator:

The steps for selecting the size of an induction generator are as follows:
1 The size of induction generator:

Induction Generator kW = 1.3* -----------------------------
AxB
The rating of an induction generator, which is basically a motor, is in kW.

Therefore, the ELC factor (C) and the power factor (D) corrections are not
applicable. The constant 1.3 is the overrating factor (up to 30% recommended) to
serve similar purposes as in the case of a synchronous generator. The generator
rating (voltage and current) should not exceed 80% of the electrical motor rating.
2 The rotational speed of induction generator:
120 f
Rotational speed ( Ni ) = (1 + s )RPM
P
Where,
Ns - Nr
P and f are as same as for synchronous generator and s =
Ns
Where,
s is the slip of the generator
120 f
Ns is the synchronous speed, i.e. Ns = RPM
P
Nr is the rated rotor speed of the induction motor and Ni always exceeds Ns
while acting as a generator.

In addition to calculating electrical parameters stated above, following components are added to the
spreadsheet:
1 Computation of excitation capacitance for an induction generator.

2 Sizing of the electrical load controller (ELC) or the induction generator controller (IGC) (equal to
the installed capacity).
3 Sizing of ballast (20% higher than the installed capacity). In case the installed capacity exceeds or
equal to 50kW, the ballast capacity of ELC-Extension is calculated as:
Ballast capacity of ELC extension (kW) = 60% * 1.2 * Pe + 40% * Pe
4 Sizing of MCCB/MCB.
5 Sizing of power cables.
a) Sizing of excitation capacitance of an Induction Generator
Excitation capacitance for Delta connection C (цF) = 1/(2*pi()*f*Xc*hm)
1000*Pe* sin (cos-1 (power factor))

Or, C (цF) = -----------------------------------------------------
3*V2*pf*2*pi()*f*hm
Where,
Xc (Ω) = V / Im
Page: 58
V (V) = Rated Voltage of the motor (V) (phase to phase voltage 380/400/415)
Im (A) = Magnetizing Current = I rated at full load current (A) * sin (cos-1 (power factor))
I rated at full load current = Rated power (kW) * 1000/(V*pf)
hm = rated efficiency of motor at full load
For star connected capacitors, the excitation capacitance is three times that for the Delta
connection.
b) Sizing of MCCB/MCB (A) = 1.25*Pe * 1000/(V*pf)
Where,
1.25 = overrating factor by 25%.
Pe (kW)= Installed capacity
V (V) = Rated phase to neutral Voltage (V) (V*√3 for 3-phase)
pf = power factor if induction generator is used
c) Sizing of power cable (A) = 1.7*I
Where,
1.70 = overrating factor by 70%.
I (A) = Current = Generator size/(V *pf if induction generator is used)
V (V) = Rated phase to neutral Voltage (V) (V*√3 for 3-phase)
pf = power factor
9.3.2 Typical example of a 3-phase 60kW synchronous generator
Selection of Electrical Equipment
Name of the Project: Upper Jogmai, Ilam
INPUT
Discharge (m3/s) 0.204 Power factor 0.8
Gross head (m) 60.000 Safety factor of generator 1.3
Overall plant efficiency (%) 50% Phase 3-phase 3
Temperature (oC) 45 Type of Generator Synchrono 1
Altitude (m) 1500 Over rating factor of MCCB 1.25
ELC correction factor 0.83 Over rating factor of cable 1.5
Frequency of the system (Hz) 50 No. of poles 4
Capacity of used generator (kVA) 0 Rated rotor speed if induction generator N (rpm) 0
Delta 89%
OUTPUT
Pe Electrical output (active power) (kW) 60.04 Ok
Generator
Temp.factor 0.96 Altitude factor 0.96
Capacity (kVA) 127.70 Actual available capacity (kVA) 140.00
Synchronous rotational speed Ns (rpm) 1500
ELC capacity (kW) 60.04 Calculated Ballast capacity 1.2*Pe (kW) 72.04
Ballast capacity of ELC-Extention (kW) 67.24
Rated Voltage (V) 400 I rated for Cable & MCCB (A) at Generator side 202.08
Rating of MCCB (A) 108.32 Calculated size of MCCB (A) 135.40
Cable
Rating (A) 303.12 Size of 4-core cupper armoured cables 185
Figure 9.1: Electrical components of a 20kW 3-phase synchronous generator.
Page: 59
The electrical components presented in Figure 9.1 are computed as:
The size of synchronous generator:

Generator kVA = 1.3*-----------------------------
AxB xCxD
= 1.3*60.04/(0.96*0.96*0.83*0.8)
= 127.70 kVA
The higher size available in the market of 45kVA is used.
120 f
P
=120*50/4
= 1500 rpm
Since Pe > 50kW, the ballast capacity of ELC extension (kW) = 60% * 1.2 * Pe + 40% * Pe
= 0.6*1.2*60.04 + 0.4*60.04
= 67.24 kW
I rated for Cable & MCCB at Generator side = 1000/ V rated * Generator size /1.732
= 1000 / 400*140/1.732
= 202.08 Amp
Calculated size MCCB/MCB (A) = 1.25*Pe * 1000/(V*pf)

= 1.25*60.04*1000/(400*1.732*0.8)
= 135.40 Amp
Power cable inside the powerhouse
Rating current = 1.5*I rated

= 1.5*202.08
= 303.12 Amp
For this current a 4-core copper armoured cable of ASCR 185mm2 is chosen.
9.3.3 Typical example of a single phase 20kW induction generator

Figure 9.2 present electrical equipment sizing of the previous project with a single phase induction
generator with a rotor speed of 1450rpm.
Since the electrical output is more than 10kW, a reminder error is flagged in the adjacent cell.
The electrical components presented in Figure 9.1 are computed as:
The size of synchronous generator:

Generator kW = 1.3*-----------------------------
AxB
= 1.3*20/(0.96*0.96)
= 28.25 kW
The higher size available in the market of 30kW is used.
Page: 60
120 f
P
=120*50/4
= 1500 rpm
Rotational speed of a generator = Ns*(1+(Ns-N)/Ns)

= 1500*(1+(1500-1450)/1500)
= 1550 rpm
Selection of Electrical Equipment
Name of the Project: Upper Jogmai, Ilam
INPUT
Discharge (m3/s) 0.08 Power factor 0.8
Gross head (m) 50.968 Safety factor of generator 1.3
Overall plant efficiency (%) 50% Phase 1-phase 1
Temperature (oC) 45 Type of Generator Induction 2
Altitude (m) 1500 Over rating factor of MCCB 1.25
ELC correction factor 0.83 Over rating factor of cable 1.5
Frequency of the system (Hz) 50 No. of poles 4
Capacity of used generator (kW) 0 Rated rotor speed if induction generator N (rpm) 1450
Capacitor configuration Delta Efficiency of motor at full load 89%
OUTPUT
Pe Electrical output (active power) (kW) 20.00 Use of 3-phase generator is mandatory
Generator
Temp.factor 0.96 Altitude factor 0.96
Capacity (kW) 28.25 Actual available capacity (kW) 30.00
Synchronous rotational speed Ns (rpm) 1500 Rotational speed of the generator (rpm) 1550
IGC capacity (kW) 20.00 Calculated Ballast capacity 1.2*Pe (kW) 24.00
Excitation Capacitance (micro F) 123.16
Rated Voltage (V) 220 Irated for Cable & MCCB (A) at Generator side 170.45
Rating of MCCB (A) 113.64 Calculated size of MCCB (A) 142.04
Cable
Rating (A) 255.68 Size of 2-core cupper armoured cables 150
Figure 9.2: Electrical components of a 20kW 1-phase induction generator.
Excitation capacitance
1000*Pe* sin (cos-1 (power factor))
C (цF) = -----------------------------------------------------
3*V2*pf*2*pi()*f*hm
1000*20* sin (cos-1 (0.8))

C (цF) = -----------------------------------------------------
3*4002*0.8*2*pi()*50*0.89
= 123.16 цF
Page: 61
I rated for Cable & MCCB at Generator side = 1000/ V rated * Generator size /pf
= 1000 / 220*30/0.8
= 170.45 Amp
MCCB/MCB (A) = 1.25*Pe * 1000/(V)

= 1.25*20*1000/(220)
= 142.05 Amp
Power cable inside the powerhouse
Rating current = 1.5*I rated

= 1.5*170.45
= 255.68 Amp
For this current a 2-core copper armoured cable of ASCR 185mm2 is chosen.
Page: 62
TRANSMISSION AND DISTRIBUTION

Power generated at a powerhouse is evacuated to load centres with the help of transmission and
distribution lines. According to the Nepal Standard, 400/230V is used for distribution system whereas
400/11000V is used for transmission system. Use of these standard voltages is recommended so that the
power can be easily synchronised and evacuated to grid in future.

1 Type: Buried or suspended on wooden or steel or concrete poles.
2 Permissible Voltage drop: 10% of nominal value.
3 Conductor: ACSR or Arial Bundled Cable (ABC)
4 The ASCR specifications are presented in Table 10.1.
Table 10.1: ASCR specifications

Current
ACSR rating Equivalent Sp.
Code Type of Resistance max Copper Impedance Weight Sp. Cost
2
number ACSR Ohm/km Amps area mm Ohm/km (kg/km) (Rs/km)
1 Squirrel 1.374 76 13 0.3013 80 13000
2 Gopher 1.098 85 16 0.294 106 14500
3 Weasel 0.9116 95 20 0.288 128 15500
4 Rabbit 0.5449 135 30 0.2723 214 25750
5 Otter 0.3434 185 50 0.257
6 Dog 0.2745 205 65 0.25 394 52000

1 The presented spreadsheet is designed to calculated transmission parameters for three phase
11kV and 400V and single phase 230V transmission and distribution lines.
2 Balanced load is considered, i.e., neutral does not carries any current.
3 The rated voltage of 400V for three-phase and 230V for single phase are considered in the design.
4 With a power factor of 0.8, the rated current and voltage drop are calculated as:
Phase Current (A) Voltage drop (cV)

3-phase Power*1000/(1.732*V* power factor) 1.732*I*Z*L
1-phase Power*1000/(V*power factor) 2*I*Z*L
5 Impedance (Z) = √(Resistance^2+Reactance^2).

6 Voltage at node (Vi)
Phase Voltage at node (Vi)
Single to single phase or 3 to 3 phase Vprevious - dV
Three to single phase Vprevious/1.732 - dV
Page: 63
7 ASCR Specifications:
Current
ACSR rating Equivalent Sp.
Code Type of Resistance max Cu area Impedance Weight Sp. Cost
2
number ACSR Ohm/km Amps mm Ohm/km (kg/km) (Rs/km)
1 Squirrel 1.374 76 13 0.3013 80 13000
2 Gopher 1.098 85 16 0.294 106 14500
3 Weasel 0.9116 95 20 0.288 128 15500
4 Rabbit 0.5449 135 30 0.2723 214 25750
5 Otter 0.3434 185 50 0.257
6 Dog 0.2745 205 65 0.25 394 52000
Start
Project Node & reach names, reach lengths,

Name, phase, Power at node, ASCR code,
Location, Remarks for repeated lengths
Length Current
Length of cables of Voltage drop Resistance
Cost of cables neutral Voltage at node Reactance
cables Impedance
End
Figure 10.1: Flow chart of transmission and distribution line computation.
The grid and load presented in Figure 10.2 are used for the calculations presented in Figure 10.3.
Page: 64
Node/Load (kW)
Transformer # 1
Reach length (m)/Phase/Load (kW)
Figure 10.2: Transmission line and load used for the example.
Page: 65
Transmission and Distribution System:
Name of the project: Upper Jogmai, Ilam
Pow er at
Vrated @
Reach next node &
Reach Length Phase node ACSR Current
Node name name (km) 1,3,11 (kW) type (A)
PH-A-B-C-D 3 400.00
PH A PHA 0.450 3 16 Dog 28.87
A B AB 0.660 1 5 Rabbit 27.64
C AC 0.090 1 5 Rabbit 30.65
D AD 0.090 1 6 Rabbit 33.68
PH-T1 3 400.00
PH T1 PHT1 0.050 3 20 Otter 36.08
T1-T2 11 11000.00
T1 T2 T1 T2 1.500 11 20 Squirrel 1.31
T2-E 3 400.00
T2 E T2 E 0.300 3 20 Dog 36.08
E-J ( r ) 1 226.90
T2 J T2 J 0.300 1 20 Dog 110.18
E-H (y) 1 226.90

E F EF 0.300 1 6 Otter 33.05
F H FH 0.400 1 5 Otter 28.62
E-G (b) 1 226.90

E F EF 0.300 1 7 Rabbit 38.56
F G FG 0.200 1 5 Rabbit 29.37
E-M ( r) 1 226.90
E F EF 0.300 1 1 Squirrel 5.51
F M FM 0.600 1 1 Squirrel 5.62
F-K (y) 1 218.40

F K FK 0.180 1 2 Squirrel 11.45
F-L(b) 1 212.80
F L FL 0.180 1 1 Squirrel 5.87
Page: 66
Total length of cables (km) 7.02 0.00 10.00 2.68 1.55 2.85
Length of neutral cables (km) 10
Cost of cables(Rs.) 517720.00
Reach
Voltage Volt at node % voltag
drop (V) branch (V) drop Squirrel Gopher Weasel Rabbiit Otter Dog
400.00
8.40 391.60 2.10 1.35
22.20 203.89 13.45 1.32
3.40 222.69 3.18 0.18
3.70 222.39 3.31 0.18
400.00
1.30 398.70 0.32 0.15
11000.00
4.70 10995.30 0.04 4.50
400.00
7.00 393.00 1.75 0.90
226.90
24.50 202.40 12.00 0.60
226.90
8.50 218.40 5.04 0.60
9.80 208.60 14.35 0.80
226.90
14.10 212.80 7.48 0.60
7.20 205.60 18.09 0.40
226.90
4.60 222.30 3.35 0.60
9.30 213.00 10.74 1.20
218.40
5.70 212.70 7.52 0.36
212.80
2.90 209.90 8.74 0.36
Figure 10. 3: Typical example of a low voltage transmission line.
Page: 67
10 LOADS AND BENEFITS

By allocating different loads in different time slots, a micro hydro plant can be optimised resulting in the
maximum benefits. The presented spreadsheet may help to fulfil this objective.

13. Maximum subscription wattage should not exceed 120W per household.
13. Minimum of 10% productive end use is mandatory.
13. Multipurpose scheme is preferable.

The flow chart of the load and benefits analyses used in the spreadsheet is presented in Figure 11.1. An
example is presented in the in Figure 11.2. The main features and assumptions are:
1. For the first three years of operation, one set of domestic and five different end uses can be
defined in five different time slots in the 24-hour load duration curve.
2. Probable business load after three years of operation can defined based on the AEPC
requirements.
3. Annual available energy, annual load, productive end use load factor and annual total income are
calculated and subsequently used in the financial analyses.
4. A load duration chart for the first three years of operation is presented at the end of the
spreadsheet. This chart is very helpful in planning and allocating different load so that the benefits
are maximized.
Start
Project Installed capacity,

Name, present loads & tariff (24 hr, 5 slots)
Location, Future EU load & tariff (1 time slot)
Annual energy
24 hr load
Yearly loads
Load duration
EU factors
Graph (decision making)
Yearly income
End
Figure 11.1: Flow chart of the load and benefits calculation spreadsheet.
Page: 68
10.3.2 Typical example of loads and benefits

LOADS AND BENEFITS
INPUT
General
Power Output (kW) 96.1 Domestic lighting
Name of the Source Gadi Gad Khola Average subscription/household (W/HH) 80
Location Ladagada VDC, Doti System loss 10%
Beneficiary HH (nos.) 1035 time 0 5 8 18 20
Plant's operating days330 load 91.08 0 0 91.1 0
Loads (kWh or W/m)Operating Tariff

days/year
(Rs) Probable Business Load Expected after 3 years
Domestic 330 1 Operating
Tariff
days/year
(Rs) Load From (hr)
To (hr)
Agro-processing 330 6 Metal Workshop 330 6.00 10 12 16
Bakery 320 6.00 Photo studio 320 6.00 1 8 20
Saw Mill 300 5.00 Dairy Processing 320 6.00 8 8 18
Herbs Processing 180 5.50 Cold store 310 6.00 6 8 18
load 5 330 load 5
load 6 330 load 6
Proposed end uses and operting hours

time (hr) 0 4 12 16 22
Agro-processing 0 0 22.5 0 0
time (hr) 0 8 14 18 22
Bakery 0 9 0 0 0
time (hr) 0 3 16 18 22
Saw Mill 0 0 10 0 0
time (hr) 0 3 12 17 22
Herbs Processing 0 0 25 0 0
time (hr) 0 6 8 15 22
load 5 15 0 0 0 0
time (hr) 0 3 5 10 22
load 6 12 0 0 0 0
OUTPUT
Summary
Annual Available kWh 761112
First 3 years After 3 years
Yearly load (kWh) 117060 147680
Productive end use load factor (%) 15.38 19.40
Annual total (domestic + end uses) Income (Rs) 1,429,230 1,612,950
End Use Load Operation Period Yearly Load Annual

(kW) Hours/day Days/year kWh LF (%) Income (Rs)
Domestic Lighting 91.08 7 330 210394.8 27.64 993,600
Existing/Committed Business Load
Agro-processing 22.5 4 330 29700 3.90 178200
Bakery 9 6 320 17280 2.27 103680
Saw Mill 10 2 300 6000 0.79 30000
Herbs Processing 25 5 180 22500 2.96 123750
load 5 15 6 330 29700 3.90 0
load 6 12 3 330 11880 1.56 0
Total 117060 15.38 435,630
Total Annual Income from sales of electricity 1,429,230
Probable Business Load after 3 years

Metal Workshop 10 4 330 13200 1.73 79200
Photo studio 1 12 320 3840 0.50 23040
Dairy Processing 8 10 320 25600 3.36 153600
Cold store 6 10 310 18600 2.44 111600
load 5 0 0 0 0 0.00 0
load 6 0 0 0 0 0.00 0
Total additional annual income after 3 years 61240 8.05 183,720
Productive End Use (%) 19.40
Figure 11.2: An example of load and benefits calculation.
Page: 69
Load Duration Chart for the first three years of operation

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
140 100
90
120
80
100
70
60
80
50
60
40
30
40
20
20
10
0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
T i me (hr s)
Domestic Agro-processing Bakery Saw Mill Herbs Processing load 5 load 6 Installed Capacity
Figure 11.3: Load duration curve
It can be seen from the load duration curve presented in Figure 11.3 that the project is mainly dominated
by domestic load. Other end uses can be incorporated within 05 to 16 hours. If the project has to share
water with other existing water utilities such as irrigation system, etc. This can be arranged during the non-
operating hours or during partial load period. This load duration curve can also be used to maximize
benefits even at lower tariff during such hours.
Page: 70
13. COSTING AND FINANCIAL ANALYSES
13.1. INTRODUCTION AND DEFINITIONS

This spreadsheet tests the financial viability of the project based on the guidelines and standards set aside
by AEPC.
13.2. MGSP/ESAP GUIDELINES AND STANDARDS

1. 15 years as the economic life span of the project for calculating financial parameters.
2. Total cost of the project including subsidy should be limited to
Table 12.1: Per kilowatt subsidy and cost ceiling as per AEPC
Walking distance Subsidy Ceiling
less than 2 days walking distance 70000 150000
2-5 days walking distance 78750 158750
more than 5 days walking distance 91500 171500
3. Net present value of equity investment at a discount rate of 4% should be positive.
13.3. PROGRAM BRIEFING AND EXAMPLE

13.3.1. Program Briefing
The spreadsheet presented takes the total costs, financing of the project and annual cost as inputs to
calculate the financial parameters such as the net present value, cost per kilowatt, etc. The flow chart on
which the spreadsheet is based is presented in Figure 12.1. Annual cash flows for the stated planning
horizon is presented and used to calculate different financial parameters.
Start
Sources of investment
Project Payback of loan
Name, Discount factor
Location, Breakdown of investment cost
Annual operating cost
NPV w & w/o probable business load

Cost per kW
Subsidy per HH
Cash flows
End
Figure 12.1: Flow chart for Project costing and financial analyses.
Page: 71
13.3.2. Typical example of costing and financial analyses

A typical example of costing and financial analyses based on the flow chart presented in Figure 12.1 is
presented in Figure 12.2.
Project Costing and Financial Analyses

INPUT
Total Project Cost (Rs.) 8,516,715
more than 5 days walking distance Subsidy/kW Total subsidy Bank loan Other loan Cash equity Kind equity Others
91,500 4575000 1,890,044 1,200,000 851,671 0
Interest rate (%) 3%
Payback period (yr) 7
Plant life (yr) 15
Discount Rate (%) 4%
Investment Cost (Rs) 8,516,715

Mechanical components 999,040 Installation 232,500
Electrical component 2,061,717 Commissioning 0
Civil component 1,363,497 VAT 623,611
Spare parts & tools 57,550 Contingencies 0
Transport. 3,178,800 Others
Annual Operating Cost (Rs) 305,004

Salary Spares Maintenance Office expenses Miscellaneous Others
114,000 0 171,000 20,004
Summary
Without With
probable probable
business load business
Project cost (Rs) 8,516,715 NPV on ====>>> (Rs) load (Rs)
Annual Operation, Maintenance and other Costs (Rs) 305,004 Total cost (4,367,625) (4,135,377)
Annual Income without probable business loads (Rs) 826230 Total Cost -Subsidy 31,413 263,662
Annual Income with probable business loads (Rs) 855180 Equity 2,667,678 2,899,926
Annual installment for Bank loan 303364 After Loan Repayment 3,509,282 3,704,195
Annual installment for other loan NA

NPV on equity without probable business load (Rs)+ve 2,667,678
NPV equity with probable business load (Rs)+ve 2,899,926
Cost/Kw =>>Ok 170,334
Subsidy/HH 9,713
Cash Flows
Ye ar =>> 0 1 2 3
A nnua l inc o m e wit ho ut pro ba ble bus ine s s lo a ds 826230 826230 826230
A nnua l inc o m e wit h pro ba ble bus ine s s lo a ds 826230 826230 826230
T o t a l E quit y 1200000
A nnua l O & M c o s t s 305,004 305,004 305,004
Lo a n re pa ym e nt 303364 303364 303364
C a s h f lo w wit ho u t pro ba ble bus ine s s lo a d -1200000 217862 217862 217862
C a s h f lo w wit h pro ba ble bus ine s s lo a d -1200000 217862 217862 217862
4 5 6 7 8 9 10 11 12 13 14 15
826230 826230 826230 826230 826230 826230 826230 826230 826230 826230 826230 826230
855180 855180 855180 855180 855180 855180 855180 855180 855180 855180 855180 855180
305,004 305,004 305,004 305,004 305,004 305,004 305,004 305,004 305,004 305,004 305,004 305,004
303364 303364 303364 303364 0 0 0 0 0 0 0 0
217862 217862 217862 217862 521226 521226 521226 521226 521226 521226 521226 521226
246812 246812 246812 246812 550176 550176 550176 550176 550176 550176 550176 550176
Figure 12.2: A typical example of project costing and financial analyses.
Page: 72
13. UTILITIES
13.1. INTRODUCTION
In this spreadsheet small tools for independent calculations are presented. These calculations are similar
to the calculations presented in other spreadsheet for individual components. The main aim of these
small calculations is to provide quick and handy computation of:
1. Uniform depth of a rectangular or trapezoidal canal.
Uniform Depth of a Trapezoidal Canal (Y-m)

Design Discharge (l/s): 200.000
1/Mannings Coeff (M): 65.0000
1/Canal Slope (S): 50
Width of Canal (b-m): 0.500
Unlined firm/gravelyl/clay/side hill c/s in average loam cut (z m) 1
Uniform Depth (Y-m) 0.150
2. Payment of loan for different periods such as monthly, quarterly and yearly.
Payment of a loan
Loan amount: 1,800,000
Interest rate (APR): 6.00%
Monthly payments and No 12
Monthly Payment 154,919.57
3. Power calculations
Power MGSP-ESAP (Pe-kW)

Discharge (l/s): 160
Cumulative efficiency(n%) 65.00%
Head (H-m) 27.50
Actual Power (Pact-kW) 28.06
Power MGSP-ESAP (Pe-kW) 21.58
4. Spillway sizing.
Spillway Lengths (m)

Flood discharge (l/s): 540
Design discharge (l/s): 126
Overtopping height (ho) mm: 150
Spillway discharge coeff 2.1 2.1
L spillway min for Qf m & full height 4.43
Length of spillway Ls1 for Qf m & half height 9.60
Page: 73
5. Voltage drops of transmission line.
Voltage Drop
Reach length (km) 7.000
Voltage at 1st node (V) 11,000
Power (kW) 190
ASCR type Squirrel 1.00
Phase at 1st node (1/2/11(for 11kV or above) 11
Phase at 2nd node (1/2/11(for 11kV or above) 11
Current (A) 12.47
Impedence Ohm/km 1.3803
Voltage at 2nd node (kV) 208.6V ,1.9% 10,791.40
6. Pipe friction factor.
Friction Factor (f) & Net head

Discharge (m3/s) 0.160
Gross head (m) 20
Pipe roughness ks (mm) 0.060
Pipe diameter (m) 260.00
Pipe Length (m) 140
Turbulent headloss factor (K) 1.50
Friction factor f 0.0153
Net Head (m), hl=4.52m 22.59% 15.48
Page: 74
13. REFERENCES
1. Mini-Grid Support Programme, Alternative Energy Promotion Centre, Kathmandu, Nepal (2002),
Peltric Standards
2. Mini-Grid Support Programme, Alternative Energy Promotion Centre, Kathmandu, Nepal (2003),
Preliminary Feasibility Studies of Prospective Micro-hydro Projects
3. Mini-Grid Support Programme, Alternative Energy Promotion Centre , Kathmandu, Nepal(2001),

Technical Details and Cost Estimate
4. Mini-Grid Support Programme, Alternative Energy Promotion Centre , Kathmandu, Nepal(2003),

Guidelines for Detailed Feasibility Study of Micro-Hydro Projects
5. European Small Hydropower Association (1998), Layman's Guidebook on How to Develop a Small
Hydro Site
6. BPC Hydroconsult, Intermediate Technology Development Group (ITDG), Kathmandu, Nepal

(2002), Civil Works Guidelines for Micro-Hydropower in Nepal.
7. United Nations Industrial Development Organization (UNIDO), Report on Standardiztion of Civil

Works for Small Hydropower Plants
8. GTZ/Department of Energy Development, Energy Division, Papua New Guinea, Micro Hydropower
Training Modules (1994), Modules 1-7, 10, 13, 14 & 18B.
9. Americal Society of Civil Engineer (ASCE), Sediment Transportation.
10. KB Raina & SK Bhattacharya, New Age International (P) Ltd (1999), Electrical Design Estimating
and Costing.
11. Badri Ram & DN Vishwakarma, Tata McGraw-Hill Publishing Company Limited, New Delhi 1995,
Power System Protection and Switchgear, 1995.
12. Adam Harvey et.al. (1993), Micro-Hydro Design Manual, A guide to small-scale water power
schemes, Intermediate Technology Publications, ISBN 1 85339 103 4.
13. Allen R. Inversin (1986), Micro-Hydropower Sourcebook, A Practical Guide to Design and
Implementation in Developing Countries, NRECA International Foundation, 1800 Massachusetts
Avenue N. W., Washington, DC 20036.
14. Helmut Lauterjung/Gangolf Schmidt (1989), Planning of Intake Structures, GATE/GTZ, Vieweg.
15. HMG of Nepal, Ministry of Water Resources, Water and Energy Commission Secretariat,
Department of Hydrology and Meteorology, Methodologies for estimating hydrologic characteristics
of ungauged locations in Nepal (1990).
16. HMG/N, Medium Irrigation Project, Design Manuals, 1982
17. His Majesty's Government of Nepal, Ministry of Water Resources, Department of Irrigation,
Planning and Design Strengthening Project (PDSP), United Nations Development Programme
(NEP/85/013) / World Bank, Design Manuals for Irrigation Projects in Nepal, 1990.
18. ITECO, DEH/SATA Salleri Chialsa Small Hydel Project (1983), Technical Report.
Page: 75
19. P.N. Khanna (1996), Indian Practical Civil Engineer's Handbook, 15th Edition, Engineer's
Publishers, Post Box 725, New Delhi - 110001.
20. ITDG, Electrical Guideline For Micro-Hydro Electric Installation.
21. REDP, REDP Publications, Environment Management Guidelines, 1997
22. ITDG, IT Nepal Publications, Financial Guidelines for Micro-hydro Projects, 1997
23. IT Nepal Publications, Management Guidelines For Isolated MH Plant In Nepal, 1999.
24. ITDG, prepared for ESAP, Guidelines relating to quality improvement of MH plants, 1999
25. ICIMOD, Manual for Survey and Layout Design of Private Micro Hydropower Plants.
26. Norwegian Water Resources and Energy Administration, The Norwegian Regulations for Planning,
Construction and Operation of Dams, Norwegian University Press, Oslo, Norway, 1994.
Page: 76
APPENDICES
Page: i
Page: ii
Page: iii
Page: iv
Page: v
Page: vi
Page: vii
Page: viii
Page: ix
Page: x
Page: xi
Page: xii
Page: xiii
Page: xiv
Page: xv
Page: xvi
Page: xvii
Page: xviii
Page: xix
Page: xx
Page: xxi
Page: xxii
Page: xxiii
Page: xxiv
Page: xxv
Page: xxvi
Page: xxvii
Page: xxviii
Page: xxix
Page: xxx
Page: xxxi
Page: xxxii
Page: xxxiii
Page: xxxiv
Page: xxxv
Page: xxxvi
Month Regions
1 2 3 4 5 6 7
January 2.40 2.24 2.71 2.59 2.42 2.03 3.30
February 1.80 1.70 1.88 1.88 1.82 1.62 2.20
March 1.30 1.33 1.38 1.38 1.36 1.27 1.40
April 1.00 1.00 1.00 1.00 1.00 1.00 1.00
May 2.60 1.21 1.88 2.19 0.91 2.57 3.50
June 6.00 7.27 3.13 3.75 2.73 6.08 6.00
July 14.50 18.18 13.54 6.89 11.21 24.32 14.00
August 25.00 27.27 25.00 27.27 13.94 33.78 35.00
September 16.50 20.91 20.83 20.91 10.00 27.03 24.00
October 8.00 9.09 10.42 6.89 6.52 6.08 12.00
November 4.10 3.94 5.00 5.00 4.55 3.38 7.50
December 3.10 3.03 3.75 3.44 3.33 2.57 5.00
Page: xxxvii
Page: xxxviii
Page: xxxix

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MICRO-HYDROPOWER DESIGN AIDS MANUAL

Kathmandu, March 2004

Small Hydropower Promotion Mini-Grid Support Programme

7 PENSTOCK AND POWER CALCULATIONS 50

9 ELECTRICAL EQUIPMENT SELECTION 56

TRANSMISSION AND DISTRIBUTION 63

10 LOADS AND BENEFITS 68

13. COSTING AND FINANCIAL ANALYSES 71

CONTACT & ACCESS CONTACT & ACCESS

Alternative Energy Promotion Centre (AEPC) is a government organization established to promote

1.2 OBJECTIVES OF THE DESIGN AIDS

1.3 SOURCES OF THE DESIGN AIDS

1. Updated AEPC micro hydropower guidelines and standards.

1.4 DESIGN AIDS: TYPICAL DRAWINGS

1. Minimum required details such as plans and adequate cross sections.

Table 1.1: Summary of Drawings

Figure 1.1: A typical Gravel Trap Drawing

1.5 DESIGN AIDS: SPREADSHEETS

Table 1.2: Summary of Spreadsheets

10 Electrical Chapter 8: Selection of electrical equipment such as different types of

1.5.1 Flow chart notations

Start and End

Processing formulas and output

Processing and output from other sub routine

1.5.2 Iterative Processes

iterative features in Excel can be activated by selecting Calculations tab (Tools->Options-

Figure 1.3: Activation of iteration (Tools => Option =>Calculations

Figure 1.4: Macro security and enabling

1.5.4 Individual vs. linked spreadsheets

1.5.5 User specific inputs

1.5.6 Interpolated computations

1.5.8 Cell notes

Figure 1.5: Cell formula incorporated in a cell note.

1.5.9 Cell Text Conventions

Figure 1. 7: Colour coding of cell texts

1.5.10 Types of input values

Figure 1.8: Different categories of inputs.

1.5.11 Pull Down menus and data validation

Some inputs such as the name of the month, MIP hydrological

Figure 1.9: Different categories of inputs.

Table 2.1: Input parameters for Salt Dilution Method

Stream Flow, Q = M x k/A, where

Area (A) = (Sm– nr x mbaseline) * dt

Area (A) = (Sm– nr x mbaseline) * dt

Discharge (Q) = M x k/A

Water temp: 11 deg C Date: 12-Jan-04

Salt Const. (k) 1.8000

Discharge Measurement by Conductivity

Time Reading 1 Reading 2 Reading 3 Reading 4

3.1 HYDROLOGY AND NEPALI MHP

As stated earlier, almost all potential micro hydropower project

3.2 HYDROLOGICAL DATA

Figure 3.2: Hydrological Data and MHP

3.3 MEDIUM IRRIGATION PROJECT (MIP) METHOD

Figure 3.1: MIP Regions

Table 3.1: MIP regional monthly coefficients

Figure 3.5: Need of interpolation for calculating mean monthly coefficient

Interpolation of April 1, 15 and 30 data

Area of basin below 3000m elevation A3000 km2: 65

E rro rs G e ne rate d b y u sin g mid mo nthly flow s

Figure 3.6: Effect of interpolation on mean monthly flows

3.4 WECS/DHM (HYDEST) METHOD

3.4.1 Flood Flows:

A surface S = 1/k1(t+b)/b Q/Vo * 1/ sin f

Kappa (c) = 0.00008b^2 - 0.0097b + 0.9992 (by curve fitting)